EP2274485B1 - Paper layer for producing a planar printed or printable component - Google Patents

Description

The invention relates to a paper layer with the preamble features of claim 1.

Furthermore, the present invention relates to a sheet-like, printed or printable component with a paper layer of the aforementioned type and a method for producing such a component.

From the EP - A - 1 044 822 , of the EP - A - 0 054 405 and the DE 197 15 268 A1 paper layers are already emerging which can be used for producing a component, in particular for floor, wall, ceiling and / or furniture applications, wherein the respective paper layer has a fiber structure comprising fibers and an ink receiving mass is provided on the upper side in the fiber structure.

Paper layers for the production of flat, printed or printable components for floor, wall, ceiling or furniture applications are also known in practice. In a known printing paper, a color receiving layer is applied to the fiber structure of the actual paper layer. Investigations carried out by the Applicant have revealed that the particles of the ink-receiving layer averaged a few micrometers. The ink-receiving layer, which has as main constituents silicon dioxide and titanium dioxide, is applied over the entire surface of the top of the paper structure and rests on it, completely covering and hiding the paper structure. In the investigations made by the Applicant, it has been found that while the ink receptive layer is superficially engaged in the fibrous structure, it is disposed substantially over the fibrous structure and covers and covers the fibers and interstitial spaces therebetween. Ultimately results in the known paper, a substantially closed uniform surface, resulting in a very good print result.

The applicant has then further found that there are considerable problems with the necessary for the further processing of the paper Beharzen results. If the known paper is doctored after printing from above, it has been found that a sufficient and full-surface through-curing of the paper can not be guaranteed. The consequence is that the paper does not sufficiently connect with the component after being pressed.

To solve the above problem in the known paper, the applicant has then tried to inset the paper from below, as is fundamentally understood from the EP 1 749 676 A1 is known. This publication relates to a method and an apparatus for producing a paper web which can be printed by means of an ink-jet printing process and which is subsequently applied to plates or sheets. The aim is to provide an ink jet printing method, wherein the print result on the surface of the objects to be printed corresponds to the highest quality requirements in terms of appearance. For this purpose, it is provided that an absorbent along its entire thickness for liquid resin paper web is soaked from the bottom with liquid resin so that the resin does not completely penetrate the paper web, so that the other side of the paper web is at least substantially free of synthetic resin. In the end, the one from the EP 1 749 676 A1 known paper web on an upper side, substantially resin-free area, which accounts for about 50% of the thickness of the paper web. However, it has been found in experiments that when pressing the underside-resinated paper web with a component arranged on the underside and a protective layer provided on the upper side, although a sufficient connection of the paper web results to the component, but not from the protective layer to the paper web.

Object of the present invention is to provide a paper layer of the type mentioned in the one hand, a very good printing result is possible and in the other hand, a good connection to the body of a component and optionally to an upper-side protective layer is ensured.

To achieve the above object, it is provided that at least on the upper side in the fiber structure, a color receiving mass is provided, which at least substantially covers the upper side region of the fibers, and that at the top of the paper layer open spaces of the sheathed fiber structure remain so are not covered by the ink receptive mass. At least on the upper side can be provided in the fiber structure, a color receiving mass having an average particle size of less than 1000 nm. Alternatively, the fibers of the fibrous structure on the upper side are only partially covered with an ink receptive mass, which may be embedded in the fiber structure and / or applied to this, so that remain at the top of the paper layer open spaces of the fiber structure.

The invention is based, first of all, on the basic idea of providing a dye-receiving mass as a so-called pigment coating onto which the printing ink or ink is applied. At the same time, it is the case that no quasi-closed, level surface is provided by the ink receiving mass. In the sheathing of the fibers or the use of ink receptive particles in the nanoscale remain uncovered, outwardly open spaces in the fiber structure, which ensure a sufficient Durchtharzarzung the paper layer. If the upper side of the fiber structure is only partially covered with the ink receptive mass, free areas always remain, which likewise ensure the necessary through-etching.

In theoretical considerations, the inventive solution has been rejected by the applicant first, because it was feared that the paper layer with the embedded or applied ink composition, in the end, despite the ink receiving mass nor the structure caused by the cellulose fibers is recognizable, do not achieve a sufficient print result leaves. Ultimately, the invention results in no closed, substantially flat pressure surface as in the prior art. In practical experiments that have been carried out, however, has been found that the achievable in the paper according to the invention printing result is not or only slightly different from the printed result, which is achieved in the known paper mentioned above.

Incidentally, the invention offers the possibility that the paper layer can be printed with the color receiving material both before and after application to the main body of a component. So it is possible on the one hand to print the paper first and to stock it after printing, for example, on rolls or sheets. Subsequently, the printed paper layer be pressed with the body of the component under the influence of pressure and heat, the resin first melts and then cured immediately. Alternatively, it is possible to apply a teilbeharzte and unprinted paper layer with the embedded or applied ink composition first on the body in the manner described above and then to print the base body with the already applied paper layer.

In order to largely preserve the fiber structure and thus the spaces between the fibers at the top of the paper layer or uncovered and on the other hand to provide a comprehensive sheathing of the upper-side fibers and thus a good ink absorption area, the particles of the ink receiving mass should have an average diameter between 50 nm and 400 nm, preferably between 100 nm to 300 nm and in particular between 150 nm and 250 nm. Very good tests have been achieved with particle sizes in the range of about 200 nm in diameter.

In scanning electron microscopic investigations, it has been found that a plurality of intermediate spaces with a length of greater than 20 μm, preferably greater than 30 μm and in particular greater than 40 μm should be provided on the upper side of the paper layer between the fibers coated or coated with the ink receiving mass. It is understood that gaps with a length significantly greater than 40 microns can be provided. Furthermore, the gaps should have an opening area of greater than 250 nm ² , preferably greater than 500 μm ² and in particular greater than 750 μm ² . Again, it is understood that significantly larger opening areas than 750 microns ² can be provided. At intervals with the aforementioned dimensions results in an excellent Durchbeharzung the paper layer according to the invention regardless of whether the Beharzung from above or from below is carried out.

Incidentally, it is particularly advantageous in the case of the paper according to the invention if the abovementioned dimensions of the intermediate spaces are not only provided "sporadically", but if they are located on the entire upper side of the paper layer. It has been found that on the upper side per unit area [nm ² ] on average at least one gap, preferably more should be provided as three and in particular more than ten spaces of the aforementioned type.

In order to prevent the interstices between the cellulose fibers of the fiber structure from being closed by the ink receiving composition, the basis weight of the ink receiving composition should preferably be between 0.5 g / m ² and 20 g / m ² . Thus, in the case of the paper layer according to the invention, a significantly smaller proportion of ink receiving mass is used than in the prior art. This has a considerable effect on the acquisition costs of the paper layer. Thus, the cost of the paper according to the invention by a factor of 3 less than in the initially mentioned, known from practice paper.

Incidentally, it has been found that a particularly good printing result is obtained if the dye-receiving composition in any case also titanium dioxide, barium sulfate and silicates, in particular as main components.

It is also particularly favorable that the ink receiving mass is basic. It has been found that the resin to be applied is generally basic, that is, has a pH greater than 7. Furthermore, it has been found that the resin solidifies more readily in an acidic environment than in a basic environment. In order to ensure a good through-cure, the ink composition and, where appropriate, also the paper of the fiber structure should be basic.

Incidentally, the paper or the fibrous structure should be a decorative paper which has a weight per unit area without a proportion of the resin but with an ink absorption mass of between 30 g / m ² and 300 g / m ² , preferably between 50 g / m ² and 120 g / m ² and in particular of about 70 g / m ² should have.

The paper layer according to the invention with the dye-receiving mass incorporated into the fiber structure can basically be unperforated prior to printing and can only be doctored after printing. In principle, however, it is also possible for the paper layer to be so defined from the underside prior to printing that the upper region of the fiber structure with little or no resin content preferably extends over a maximum of 30% of the thickness of the fiber structure. In particular, the upper paper layer area extends over only not more than 20% of the thickness of the paper layer and more preferably not more than 10% of the thickness of the paper layer, each individual value between 0.1% of the thickness of the paper layer and 30% of the thickness of the paper layer is possible and expressly provided as essential to the invention.

It should also be pointed out in this connection that there is in practice no exact dividing line between the upper paper layer region with little or no resin content and the lower paper layer region with high resin content, since, from the bottom, a concentration gradient of the resin from bottom to top exists such that the highest concentration of the underside is present. The transition of the upper paper layer region to the lower paper layer region is characterized by an abrupt change in the concentration gradient, while the concentration gradient from the lower side of the lower paper layer region to the upper side thereof and from the lower side of the upper paper layer region to the upper side thereof is substantially constant or continuously decreases.

Otherwise, the abovementioned values of the thickness of the upper paper layer region relate to the not yet pressed state of the paper layer, ie if the paper layer has not yet been applied to the main body of the component under the influence of pressure and / or heat.

In addition, there is a further, quite considerable advantage in the aforementioned defined Teilbeharzung. Usually, on a printed component, in any case when it is used in the floor area, an upper protective layer, which is also entrained, applied under the influence of pressure and heat. In the from the EP 1 749 676 A1 As a rule, after the protective layer has been pressed, it is known that a substantially resin-free layer region remains between the resin of the protective layer and the resin of the paper layer. Since the resin of the protective layer does not or not adequately bind to that of the paper layer, this can, as already explained at the outset, lead to detachment of the protective layer. In the context of the present invention, it has been recognized that sufficient bonding of the resin of the paper layer to the protective layer can be ensured by the comparatively large interstices between the fibers.

To achieve a defined resin layer thickness in the paper layer, the amount of the underside supplied resin portion depending on the porosity and thus the absorbency of the paper layer and the viscosity of the resin is controlled procedurally controlled. If the resination is carried out, for example, by means of a roller passing through a dipping bath, the paper layer being guided over the underside by a roller, the depth of immersion of the roller, the surface condition of the roller, the diameter of the roller, the contact pressure between these play a further process parameter the paper layer and the roller and the transport speed of the paper layer play a role. It is understood that the resin can also be applied to the paper layer in other ways, for example by nozzle application.

To achieve a defined layer thickness of the upper layer of paper layer, it is otherwise advisable that the paper layer is impregnated from the top defined with a non-mixing with the barrier liquid, such that a preferably over a maximum of 30% of the thickness of the paper layer resulting Barrier layer for the resin forms. The application of the barrier liquid can be done in the same way as the application of the resin or in principle in other ways. After the paper layer has hardened, the barrier liquid is vaporized. The space originally occupied by the barrier liquid then forms the upper paper layer area. However, it is understood that in principle it is also possible to add the barrier liquid in such a way that ultimately no defined barrier layer is produced.

It is preferred in this context that the barrier liquid includes the ink receiving composition according to the invention, which deposits in the upper paper layer region after evaporation, so that subsequently results in the sheathing or coating of the fibers.

But it is also possible that the ink composition is applied in conjunction or following the impregnation with barrier liquid. The ink receiving composition can be applied separately or together with the barrier liquid by rolling, spraying, knife coating, blade coating, air brushing, cast-coating process, film presses, presses Lein, curtain coating and / or by slot nozzle application.

The curing can be carried out with only one resin or optionally in several Beharzungsschritten also with different resins to achieve certain properties of the paper layer. After hardening, the paper layer can be dried and then the ink composition is applied. This can be followed by drying again. In an alternative embodiment, a so-called wet / wet treatment takes place. In this case, the ink receptive material is applied before the resin is completely dried, that is still in a liquid or gelled or gelled state. Subsequently, the common drying of the resinated and provided with the color receiving material paper layer.

Incidentally, in experiments which have been carried out, it has been found that the weight per unit area of the resin fraction in the paper according to the invention should be between 5 g / m ² and 300 g / m ² , preferably between 20 g / m ² and 100 g / m ² In order to ensure a good connection between the paper layer and the main body of the component and optionally the protective layer to be provided.

The resin itself is preferably a reactivatable resin, in particular an aminoplast, such as a melamine resin or a urea resin. Preference is given to resins from the group of diallyl phthalates, epoxy resins, urea-formaldehyde resins, hamsäure-Acetylsäureester copolyester, melamine-formaldehyde resins, melamine-phenol-formaldehyde resins, phenol-formaldehyde resins, poly (meth) acrylates or unsaturated polyester Resins used.

Incidentally, it has been found that, in order to obtain good printing results, it is favorable for the paper layer to be heated or heated before, during and / or after the application of the color layer. For this purpose, appropriate heating means may be provided which heat the paper layer or the ink receiving mass. This can be done for example via appropriate blower. Instead or in addition, infrared, in particular NIR heating devices and / or microwave heating devices can be provided, which act directly on the water content in the ink layer. The heating or heating can, as stated above, before, during and / or after printing done. For this purpose, one or more heaters may be provided, wherein the heating section may be provided not only selectively, but itself may also extend over a larger area, for example between 0 and 5 m and in particular between 0 and 2 m before and / or after the respective pressure point.

As preferred, a surface pre-heating and after-heating over heated surfaces, over which the paper is guided before and after printing, has proven. Conveniently, the temperature of these surfaces during preheating and / or reheating should be between 30 ° C and 40 ° C, preferably at about 35 ° C.

In the area of the printer head, good experiences have been made with a radiant heat source, which acts directly on the water content of the color layer. Here, a warming to 42 ° C has proved favorable. The removal of the resulting water vapor should take place via a controlled air flow. Incidentally, the temperature should be sensor-controlled, in particular in the region of the printer head, in order to prevent overheating or inadequate heating. In any case, the aforementioned heating leads to an immediate drying of the ink layer on the ink receiving layer as soon as the ink is dispensed from the print head, and a drying of the fiber structure. It should be pointed out in the present case that the aforementioned heating or heating also has independent inventive significance, that is, independent of the paper layer according to the invention.

After drying, the paper layer is either cut on sheets or rolled up as a continuous web. In principle, it is also possible in the method according to the invention that the printing takes place before cutting / rolling.

Furthermore, the present invention relates to a printed or printable, sheet-like component, in particular for floor, wall, ceiling and / or furniture applications, with a flat body and with an applied to the body printable or printed paper layer according to one of the preceding Claims. In the invention, it is thus the case that the paper layer according to the invention is principally printed prior to further processing and only subsequently applied to the main body of the component. However, it is also possible to first laminate the paper on a component, then to print and finally to paint or otherwise to coat. The paper according to the invention is therefore not limited to a particular type of production.

It is preferred that the base body has been directly coated with the paper layer in short cycle pressing. Here, the resinated paper layer hardens directly on the base plate of a corresponding press under pressure and heat melting. The essential feature of the short-cycle pressing method is, first of all, that the base body, as the carrier plate, is not allowed to give way, or only slightly, to the pressing pressure, which as a rule is between 200 and 650 N / cm ² . In addition, the base body and the paper layers to be applied must not touch the hot pressing plates during the introduction and discharge. The temperature during compression is generally between 80 ° C to 250 ° C, preferably between 140 ° C and 200 ° C. The particular temperature during pressing depends on the reactivation temperature of the resin. Finally, the critical waiting time, ie the time from the first contact of the resinated paper layer with the press plate until the necessary pressing pressure is reached, must be taken into account. The critical lay time should be extremely short.

Although it is in principle possible to print the paper layer according to the invention using all known printing methods, in particular also the gravure printing method, the printing of the paper layer is preferably carried out by means of a digital printing method, in particular an inkjet printing method. In this case, so-called inkjet digital printers are preferably used, with which excellent printing results can be achieved. In addition, unlike the gravure printing process, decors can be designed in a simple way using a computer-aided design and can be printed at short notice. Incidentally, unlike the gravure printing method, it is also possible for the paper layer to be printed only after it has been cured.

For printing, solvent-containing ink and / or water-containing ink are preferably used. In principle, UV-based color systems can also be used. However, these have the disadvantage of odor development. In addition, problems may arise during pressing.

Moreover, the present invention relates to a method for producing a printed or printable sheet-like component of the aforementioned type, wherein the process characteristics of the aforementioned embodiments readily arise.

Moreover, it is expressly pointed out that the aforementioned and following range indications and intervals include all individual values and intermediate intervals within the ranges and intervals also in the decimal range and are considered essential to the invention, without any explicit mention of individual values or intermediate intervals or intermediate range information required.

Embodiments of the invention will be described in more detail with reference to the drawing.

Fig. 1

eine schematische Querschnittsansicht einer erfindungsgemäßen Papierschicht,

Fig. 2

eine schematische Querschnittsansicht einer bedruckten und durchbeharzten Papierschicht,

Fig. 3

eine schematische Querschnittsansicht eines flächigen Bauteils, auf dessen Grundkörper die Papierschicht aufgebracht ist,

Fig. 4

eine vergrößerte Darstellung der Oberseite der erfindungsgemäßen Papierschicht,

Fig. 5

eine der Fig. 4 entsprechende Ansicht der Oberseite einer bekannten Papierschicht im gleichen Maßstab wie Fig. 4,

Fig. 6

eine der Fig. 4 entsprechende Ansicht der Oberseite der erfindungsgemäßen Papierschicht in weiter vergrößertem Maßstab,

Fig. 7

eine der Fig. 4 entsprechende Ansicht der Oberseite der bekannten Papierschicht im gleichen Maßstab wie die Darstellung gemäß Fig. 6,

Fig. 8

eine der Fig. 4 entsprechende Ansicht der erfindungsgemäßen Papierschicht in weiter vergrößertem Maßstab,

Fig. 9

eine der Fig. 4 entsprechende Ansicht der Oberseite der bekannten Papierschicht im gleichen Maßstab wie die Darstellung gemäß Fig. 8,

Fig. 10

ein Ablaufschema des erfindungsgemäßen Verfahrens zur Herstellung eines erfindungsgemäßen Bauteils und

Fig. 11

ein alternatives Ablaufschema des erfindungsgemäßen Verfahrens.

It shows

Fig. 1

a schematic cross-sectional view of a paper layer according to the invention,

Fig. 2

a schematic cross-sectional view of a printed and durchbeharzten paper layer,

Fig. 3

a schematic cross-sectional view of a sheet-like component, on whose base body the paper layer is applied,

Fig. 4

an enlarged view of the top of the paper layer according to the invention,

Fig. 5

one of the Fig. 4 corresponding view of the top of a known paper layer on the same scale as Fig. 4 .

Fig. 6

one of the Fig. 4 corresponding view of the upper side of the paper layer according to the invention in a further enlarged scale,

Fig. 7

one of the Fig. 4 corresponding view of the top of the known paper layer in the same scale as the illustration according to Fig. 6 .

Fig. 8

one of the Fig. 4 corresponding view of the paper layer according to the invention in a further enlarged scale,

Fig. 9

one of the Fig. 4 corresponding view of the top of the known paper layer in the same scale as the illustration according to Fig. 8 .

Fig. 10

a flow chart of the inventive method for producing a component according to the invention and

Fig. 11

an alternative flowchart of the method according to the invention.

In Fig. 1 schematically a paper layer 1 is shown. The paper layer 1 consists of a conventional absorbent or liquid receptive paper material, in this case of decorative paper. The decorative paper has a in the Fig. 4 . 6 and 8th recognizable fiber structure, which is composed of a plurality of fibers, in this case cellulose fibers. As such, the paper layer 1 may be part of a roll or a sheet. In the present case, the paper layer 1 has an upper side 2 for subsequent printing and a lower side 3, which is provided for placement on the base body 4 of a component 5. The component 5 can be any flat, printed or printable element which can be used in the area of floor, wall, ceiling and / or furniture. In particular, the component 5 is a plate or a panel.

Although the Fig. 4 . 6 and 8th show only a view of the top of the paper layer 1, it follows from these representations that the paper layer 1 has a plurality of fibers 6, which ultimately form a three-dimensional fiber structure 7. Between the individual fibers 6 there are gaps 8.

As it turned out Fig. 1 shows, a color receiving mass 9 is provided on the upper side in the fiber structure 7, which ultimately in the fiber structure 7 at least in Substantially formed on the top side ink receptive layer. The ink receiving mass 9 is not or only slightly over the fiber structure 7 upwards over. Since the ink receiving mass 9 is very fine-grained, namely particles with an average diameter in the nano range, the ink receiving mass 9 sheathed the fibers 6 of the upper portion of the fiber structure 7. Due to the fine granularity of the particles of the ink receiving mass 9 remain at the top of the sheathed fiber structure 7, the also the upper side 2 of the paper layer 1 forms, open spaces 8. This results in particular from the Fig. 4 . 6 and 8th , which also illustrate that the ink receiving mass 9 does not overlap the top of the fiber structure 7 in such a way that the fibers 6 are no longer recognizable as such. The fibers 6 remain as at least partially uncovered.

The Fig. 4 . 6 and 8th make it clear that, in spite of the upper-side ink receiving mass 9, the fiber structure 7 is at least partially still recognizable and open spaces 8 remain between the fibers 6. This feature ultimately represents the decisive difference with the prior art, as can be seen from a comparison with the Fig. 5 . 7 and 9 results. The two aforementioned figures show that the fiber structure of the known paper layer is no longer recognizable there. The top of the paper layer is formed by a coarse ink receptive layer. The diameter of these particles is on average a few micrometers. In contrast to the paper layer 1 according to the invention, the ink receiving mass ultimately rests on the fiber structure due to the comparatively coarse particles, covers them and completely covers them so strongly that they are no longer recognizable. As a result, there are no open spaces between the fibers open at the top.

The between the individual particles in the Fig. 5 . 7 and 9 shown ink receptive layer provided spaces in the known paper layer are relatively evenly distributed and have both a small length and a small opening area. This is different from the paper layer 1 according to the invention Fig. 4 . 6 and 8th results, the spaces 8 between the fibers 6 of the fiber structure 7 are distributed very unevenly, have a much greater length and a much larger opening area than in the prior art. Finally, in the case of the paper layer 1 according to the invention, a multiplicity of intermediate spaces 8 with a length of greater are Provided 40 microns and an opening area of greater than 750 microns ² . Such large gaps 8 are ultimately over the entire paper layer 1 - albeit unevenly or irregularly - distributed, wherein per unit area [mm ² ] an average of more than 10 such spaces 8 are provided.

The basis weight of the ink receiving mass 9 is comparatively low and in the present case is around 5 g / m ² . Such a low weight per unit area is sufficient for the small particle size, which is about 200 nm on average, in order to cover at least the fibers 6 in the upper region of the fiber structure 7 and at the same time leave a sufficient number of gaps 8 open. It should be noted, however, that it differs from the description in Fig. 1 , In principle, it is also possible that the ink receiving mass 9 extends into the central region, the lower region or even to the bottom 3 of the fiber structure 7. In any case, however, it is necessary for the necessary refining that in each level of the fiber structure 7, the previously described open spaces are present.

The ink receiving composition 9 itself has as main constituents titanium dioxide, barium sulfate and silicates and is otherwise basic.

As previously mentioned, the fibrous structure 7 of the paper layer 1 is formed by a decorative paper having a basis weight as shown in FIG Fig. 1 shown, that is without Beharzungsanteil but with ink receptive mass 9, of about 70 g / m ² . It is understood that the decor paper can also have a much smaller or a much larger basis weight. In the Fig. 1 illustrated paper layer 1 is unprinted and unbeharzt. The paper layer 1 is first printed for further processing, that is provided with a print layer 10 and then resined. This condition is in Fig. 2 shown schematically, wherein the paper layer 1 is fully durchbeharzt over its entire thickness. In this case, the resin concentration over the thickness of the paper layer 1 may in principle be the same or else vary from one side to the other or else from both sides toward the middle. In any case, the resin, which is preferably a melamine resin, or its viscosity is so tuned to the type of paper material of the paper layer 1 and also on the Beharzungsverfahren that a complete Durchbeharzung the paper layer 1 on their entire thickness is guaranteed. The weight per unit area of the tanker fraction in the present case is about 80 g / m ² .

It should be pointed out that the paper layer 1 before printing can also be defined in such a way from the underside 3 that the upper region of the fiber structure 7 with little or no resin content exceeds a predetermined thickness, preferably over a maximum of 30% of the thickness of the fiber structure 1 extends.

In the present case, the printing or ink layer 10 has been applied by means of an inkjet digital printer (not shown), that is to say by means of the inkjet printing process, although other printing processes, in particular gravure printing, are also possible. Both solvent-based and water-based inks can be used as printing inks.

In Fig. 3 Partial detail of the component 5 is shown, which has the already mentioned planar base body 4, in particular with a rectangular shape. The main body 4 may be constructed in one or more layers and in particular consist of wood and / or plastic materials. In particular, the component 5 can be wood-based panels, such as MDF, HDF or DKS boards or so-called HPL (High Pressure Laminate) boards. The component 5 may also be thicker foils, cardboard or plasterboard.

At the in Fig. 3 shown component 5 is applied to the top 11 of the base body 4, the printed paper layer 1 and thus firmly connected. Furthermore, a protective layer 12 is applied to the printing layer 10. The protective layer 12, which is also resined, serves to protect the printing layer 10 from UV radiation and in particular from mechanical damage. In order for the printing layer 10 to still be recognizable, the protective layer 12 is transparent. In the protective layer 12 can be very hard particles such as corundum incorporated. It should be pointed out that the protective layer 12 is generally realized in the case of those components 5 which are used in the floor area. In principle, however, the protective layer 12 can also be dispensed with. This applies in particular to wall and ceiling applications as well as furniture elements.

In Fig. 10 is schematically illustrated the inventive method in a short-cycle press method. The process begins with the known production of the paper in a paper machine, which is shown in process step A. The paper layer 1 is still part of a quasi-infinite paper web.

The paper production is followed in step B by a surface treatment by smoothing the upper side 2 to equalize the surface and optionally subsequent fine roughening of the previously smoothed surface. Subsequently, the ink receiving mass 9 on or in the top 2 up or, introduced.

After the surface treatment of the provided with the ink receiving mass 9 paper layer 1, the printing and thus the order of the printing layer 10 in step C. The printing takes place in the inkjet printing process via inkjet digital printer. When printing, the paper layer 1 may still be part of a paper web or already part of a cut from the paper web sheet. The cutting on sheets can also be done later. However, part of process step C is also the heating of the paper layer before, during and / or after the application of the color layer. In the present case, the paper layer 1 is preheated between 30 ° C. and 40 ° C., preferably at about 35 ° C., so that the ink already encounters the preheated ink layer during printing, which promotes drying. When applying the ink, heating takes place via a radiation heater at 42 ° C., which is directed onto the region of the paper layer 1 that is being printed. Finally, even after printing via a third heating device (for example, via a heated base plate), so-called after-heating likewise takes place between 30 ° C. and 40 ° C.

In process step D, the complete through-etching of the printed paper layer 1 takes place, so that the state according to FIG Fig. 2 results.

In method step E, the paper layer 1 is pressed with the base body 4. At the same time, the protective layer 12 is pressed in a corresponding pressing device. Under the pressure and heat of the pressing plates of the pressing device, the resin melts in the paper layer 1 and the resin in the Protective layer 12 and cures directly during the pressing process, so that on the one hand a firm connection of the paper layer 1 to the base body 4 and on the other hand, a firm connection of the protective layer 12 results on the paper layer 1. Due to the hardening of the paper layer 1, moreover, during pressing, such a firm connection occurs between all layer materials, which does not have to be feared due to unintentional detachment.

In Fig. 11 schematically an alternative embodiment of the method is shown. The process steps a and b correspond to the aforementioned process steps A and B of papermaking and the application of the ink receiving mass. This is followed by the method step c, wherein the paper web is teilbeharzt from its underside. The Teilbeharzung done defined so that the upper portion of the fiber structure 7, but in any case the top of the fiber structure 7 and the ink receiving mass 9 located there, remain at least substantially resin-free.

In method step d, the paper layer 1, which is then already cut on sheets, applied to the base body 4 by pressing in the mentioned pressing device. The paper layer 1 is still unprinted in this case and also has no upper-side protective layer 12.

After pressing the still unprinted paper layer 1 on the base body 4, the unprinted component 5 is now also printed in the method step e in the inkjet printing process. Parallel to this or immediately afterwards, the heating of the applied printing layer 10 takes place. Here, too, of course, a preheating of the paper layer 1 can be made. This is followed by the final compression of the protective layer 12 in the pressing device in method step f, in order to connect the protective layer 12 to the paper layer 1 after melting and curing of the resin in the protective layer 12.

Although that in Fig. 11 shown schematic method is more complicated in terms of process, it has the advantage that non-printed components 5 can be readily maintained and the printing can be made according to customer requirements, if necessary, at short notice.

LIST OF REFERENCE NUMBERS

1

paper layer

2

top

3

bottom

4

body

5

component

6

fibers

7

fiber structure

8th

interspaces

9

Color recording Mass

10

print layer

11

top

12

protective layer

Claims (14)

1. Paper layer (1) for manufacturing a planar, printed or printable component (5), in particular for floor, wall, ceiling and/or furniture applications, wherein the paper layer (1) before or after the printing process is intended for being applied on a planar basic body (4) of the component (5), under the influence of pressure and/or heat, wherein the paper layer (1) has a fiber structure (7) comprising fibers (6) and wherein interspaces (8) are provided between the fibers (6),
   characterized in that
   a colorant-receiving mass (9) is provided at least at the upper side in the fiber structure (7), which mass at least substantially encases the fibers (6) in the upper area of the fiber structure (7), and in that open interspaces (8) of the encased fiber structure (7) remain at the upper side (2) of the paper layer (1).
2. Paper layer according to claim 1, characterized in that the colorant-receiving mass (9) comprises particles with an average diameter between 50 nm to 400 nm, preferably between 100 nm to 300 nm and in particular 150 nm and 250 nm.
3. Paper layer according to claim 1 or 2, characterized in that at the upper side (2) of the paper layer (1), a plurality of open interspaces (8) are provided having a length of greater than 20 µm, preferably greater than 30 µm and in particular greater than 40 µm, and/or an opening area of greater than 250 µm², preferably greater than 500 µm² and in particular greater than 750 µm².
4. Paper layer according to any of the preceding claims, characterized in that at the upper side (2) per unit of area [mm²] on average at least one interspace (8), preferably more than three and in particular more than 10 interspaces (8) are provided.
5. Paper layer according to any of the preceding claims, characterized in that the fiber structure (7) is formed by a decor paper having a grammage, without resin coating portion, however, with colorant-receiving mass (9), of between 30 g/m² and 300 g/m², preferably between 50 g/m² and 120 g/m² and in particular of approximately 70 g/m².
6. Paper layer according to any of the preceding claims, characterized in that the paper layer (1) is not treated with resin before printing and is only treated with resin after being printed, or that the paper layer (1), before printing, is treated with resin in such a defined manner from the lower side (3) that the upper area of the fiber structure (7) with a small or no amount of resin extends about maximum 30% of the thickness of the fiber structure (7).
7. Paper layer according to any of the preceding claims, characterized in that the grammage of the resin coating portion is between 5 g/m² and 300 g/m², preferably between 20 g/m² and 100 g/m².
8. Paper layer according to any of the preceding claims, characterized in that the paper layer (1) has been heated or warmed up, respectively, before, during and/or after applying the colorant layer (10) and that preferably the heating/warming up is performed at a temperature lower than the reactivation temperature of the resin and in particular in the range between 30°C and 150°C.
9. Printed or printable planar component (5), in particular for floor, wall, ceiling and/or furniture applications, with a planar basic body (4) and a printable or printed paper layer (1) provided on the basic body (4), in accordance with any of the preceding claims.
10. Component according to claim 9, characterized in that the paper layer (1) has been printed before or after the application thereof on the basic body (4).
11. Component according to claim 9 or 10, characterized in that the basic body (4) has been directly laminated with the paper layer (1) in a short-cycle pressing process.
12. Component according to any of the claims 9 to 11, characterized in that the paper layer (1) has been printed by means of a digital printing process, in particular an inkjet printing process, and that preferably solvent-containing and/or water-containing ink has been applied as printing ink.
13. Method for manufacturing a printed planar component (5) according to any of the claims 9 to 12, wherein a printed paper layer (1) according to any of the preceding claims 1 to 8 is applied on a basic body (4) of the component (5) by directly laminating the basic body (4) with the paper layer (1) in a short-cycle pressing process.
14. Method for manufacturing a printed planar component (5) according to any of the claims 9 to 12, wherein an unprinted paper layer (1) according to any of the preceding claims 1 to 8 is applied on a basic body (4) of the component (5) by first laminating the paper layer (1) onto the component (5), then printing it and finally lacquering it or coating it in another manner.

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