Direct Printed Laminate (DPL)

[+] Structure of a DPL layer

In June 2006, we were the first coating manufacturer to manage to develop a market-ready system for direct printing on HDF floors (according to AC3). This technological milestone means we have at our disposal an efficient and stable system for our customers from the laminate industry. In some areas, we even surpasses the strict requirements of the EN13329 standard for laminates!

Requirements according to AC3

Requirements AC3 (excerpt)	SPECIFICATION	ACTUAL
Abrasion resistance according to EN 13329-E (S42-method)	< 2000 cycles	> 2200 cycles
Abrasion resistance according to EN 438 – 2.14	≥ 2,5 N	3,5 N
Ball fall test according to EN 438 – 2.11	≥ 10,0 N	14,0 N
Water resistance according to EN 438 – 2.27 (48 h, 60°C)	no delamination	no delamination

Coating structure

Unlike classic laminate floor finishes, in our new method, the HDF support board is directly printed and coated in a multi-layered roller procedure. Firstly a water-based primer is applied using rollers to achieve a good adhesion between the overall structure of the coating and the HDF support board. Afterwards, 2-3 layers of hydro roller sealer are applied in the base colour corresponding to the desired décor, e.g. beech, oak etc. This is followed by printing of the multi-coloured décor.

In order to meet the requirements for an effective laminate floor, the décor needs to be protected with a highly hard-wearing, so-called colourless performance layer. This is provided using UV-cured coatings of which several layers are applied (see table above).

Nine benefits in brief:

• short cycle times

• reduced time in warehouse

• high colour flexibility

• high transparency

• surface look and feel resembling wood

• optimal sound proofing

• improved shape stability

• improved abrasive resistance

• conductivity

The successful development of the direct print method serves to underline the power to innovate and customer-orientation of Friedrich Klumpp GmbH.

01.06.06