比利时专利BE1021467B1 A METHOD AND A DEVICE FOR DECORATING A PANEL

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专利摘要:
A method of decorating a panel (7) comprises the steps of supplying a panel (7) to a carrier (3), performing at least a first printing step by means of a first printing module and performing a second printing step by means of a second printing module, wherein the first and second printing steps are performed according to a predetermined positional relationship to form the decorated panel (7), and wherein during and between the first and second printing steps the panel (7) at least approximately fixed position with respect to the carrier (3).
公开号:BE1021467B1
申请号:E2012/0793
申请日:2012-11-21
公开日:2015-11-27
发明作者:Bruno Paul Louis Vermeulen
申请人:Spanolux Nv-Div Balterio；
IPC主号:

专利说明:

A METHOD AND A DEVICE FOR DECORATING ONE. PANEL
The present invention relates to a method for decorating a panel, comprising the steps of supplying a panel to a carrier, performing at least a first printing step by means of a first printing module and performing a second printing step by means of a second print module.
Such a method is known from. EP 2 363 299. In the known method, a decorative basic pattern is printed on the panel in the first printing step. The panel is transported to a digital printing station for printing a substance to be cured on the panel in a second printing step in order to decorate the panel. Before the panel arrives at the print station, the basic pattern is recognized by a camera. The decorative basic pattern can be a simulation of natural wood with grain and knots. The substance to be cured is printed on the panel and subsequently cured in order to create a texture on the panel that can correspond to the basic pattern, if possible for obtaining a corresponding embossment-in-register print. In this way, a realistic textured surface can be made which corresponds, for example, to a natural wooden board. As a result of the required recognition process, for the digital printing station, the known method appears to be time-consuming. In addition, if the pattern of the substance to be cured is to be aligned with the decorative basic pattern, an intermediate positioning operation of the panel relative to the support and / or the second print module may be required. It is an object of the invention to provide an efficient method for decorating a panel.
This is achieved with the method according to the invention, wherein the first and second printing steps are carried out in a predetermined positional relationship to form the decorated panel, and wherein during and between the first and second printing steps the panel is at an approximately fixed position at held in relation to the carrier.
Because the panel remains in a fixed position with respect to the carrier, the second printing step can be controlled on the basis of the same coordinates as those used for the first printing step. In other words, additional steps for creating a separate digital image of a pattern printed at the first printing step, for example by means of a camera as known in the prior art, and for example calculating the coordinates that are used in the pattern for controlling the second printing step are omitted. In fact, a single reference set of coordinates can be used to calculate the coordinate sets used for both printing steps. This results in a fast manufacturing process. The coordinates can be relative to the position of the carrier. The coordinate sets used in the first and second printing steps are not necessarily identical to each other. The desired patterns that are printed at the first and second printing steps may intentionally differ from each other. However, the method according to the invention provides the opportunity to use identical coordinates in both printing steps, so that the patterns are printed exactly at the same position of the panel, i.e. on each other. This provides the possibility to perform the printing steps in a continuous process with a high degree of accuracy and in a fast manner.
The panel can be a floor panel, a wall panel, a ceiling panel, a panel for furniture, packaging or the like and suitable for indoor and / or outdoor use. The panel can be rigid or flexible and it can have numerous dimensions. It can be made of wood-based material such as MDF, HDF, WPC, or vinyl, metal, glass, stone, ceramic, textile, non-woven material, paper, cardboard, but also polymer composite. Furthermore, the panel can be applied to a different substrate, for example by laminating.
The panel can be ready for use after performing the method according to the invention. The panel to be decorated can for instance already have the desired dimensions and can already be provided with locking means for fixing the same panels together, such as grooves and tongues. It is also possible that the panel is an intermediate product after performing the method according to the invention and, for example, still has to be sawn into smaller pieces and provided with locking means. It is noted that the method before, after and between the first and second printing step may comprise more manufacturing steps, for example for preparing the panel surface for the printing steps by applying a primer, or alternative treatments such as corona, plasma, pyrolysis , heating and surface activation treatments, or the like, or treatment of the panel surface between or after the printing steps, for example by applying a protective layer or the like.
The method according to the invention is independent of the size, material composition or physical properties of the panel. For example, the method can be carried out within a larger production process as a roll-to-roll or a panel-to-panel process.
Furthermore, the duration of the first and the second printing step can be different, for example if different quantities of printing material have to be printed at both steps.
The first and / or second print module and / or any further print module may comprise an ink jet head and / or a valve jet head and / or a toner head, so that any order and combination of print heads can be selected for any desired embodiment of the method.
Preferably, the carrier has predetermined positions relative to a reference point during the first and second printing steps. This means that it is not necessary to determine the current position of the panel in the case that the carrier is moved between the first and second printing step. Relative to the reference point, the location of the panel where the first printing step is performed may be different from the location of the panel where the second printing step is performed. It is noted that the current position of the carrier relative to the reference point can be controlled, but such control is independent of the current position of the panel, or any pattern printed thereon during the first printing step, relative to the carrier . It is also conceivable to print a code on the panel in the first or second printing step, which code is related to the coordinate set of the corresponding pattern. At a subsequent production step, the data can be used for further process steps. Due to the preset positions of the carrier, high accuracy can be achieved. If the first and second print modules are digitally controlled, the desired patterns to be printed can be exchanged quickly, which leads to a high degree of flexibility.
During the first and second printing step, the carrier can follow preset paths with respect to the reference point.
In the case of the preset positions and / or the preset paths of the carrier, the locations where the first and second printing steps are performed may extend one behind the other, for example when a conveyor belt is used as a carrier. It is also conceivable that during the first printing step both the carrier and the first printing module move relative to the reference point and / or relative to each other, and / or during the second printing step both the carrier and the second printing module relative to the reference point and / or move relative to each other. The accuracy of the preset positions or trajectories depends on the accuracy of the movement of the carrier. In the case of a controlled conveyor belt, an accuracy of 5 micrometers or less can be achieved in a direction parallel to the plane of the belt and 100 micrometers or less in a direction perpendicular thereto.
In a specific embodiment, a decorative basic pattern is printed on the panel in the first printing step and in the second printing step a substance to be cured is printed on the panel, whereafter the substance to be cured is cured. This provides the opportunity to create a textured surface. As a result, it is not necessary to use relatively expensive press plates or press rolls to create a surface with pressure relief on the panel. The second printing step can take more time than the first printing step, because a relatively large amount of substance to be cured must be printed in the second printing step. However, the extra time can be minimized by performing one or more printing steps after the second printing step. In the case that the substance to be cured is formed by printing a liquid on the panel, after which a powder is applied to the liquid, so that the powder or the liquid together with the powder forms the substance to be cured, the powder can be a gel powder to reduce the duration of printing during the second printing step. Furthermore, it is possible to use customized printheads that can print relatively large quantities, more than average printheads. For example, valve jets can be used, but alternative types of printheads are conceivable.
The substance to be cured can be printed in such a way that a textured surface is created between side edges of the panel and / or that at least one side edge of the panel is chamfered. The thickness of the substance after curing can be less than 1000 microns, preferably less than 500 microns and more preferably less than 250 microns. The slope of the substance after curing can be up to 45 degrees, preferably up to 60 degrees, and more preferably up to 90 degrees relative to a panel face.
The positional ratio of the decorative basic pattern and the pattern of the substance to be cured can be such that both patterns at least approximately coincide, partially coincide, or that both patterns are offset relative to each other. Furthermore, both patterns can be printed with different materials in order to create different appearances, for example gloss and matte. It is also possible to create different forms by manipulating the hardening process. For example, when surface hardening is used instead of hardening the entire liquid, the surface may become irregular due to shrinking behavior. This can cause a matt effect.
Preferably, the substance to be cured is printed over at least a portion of the decorative basic pattern or printed adjacent to the decorative basic pattern, which provides an appearance of corresponding embossment-in-register on the panel surface. In the first case, the resulting product can obtain an increase at the location of the pattern printed at the first printing step, and in the second case, the resulting product can obtain a recess at the location of the pattern printed at the first printing step.
In general terms, the pattern of the substance to be cured can be printed at a relative position with respect to the decorative basic pattern. This may typically be desirable at the edges of the decorative base pattern, because a substance to be cured can create a faint edge. This can happen if the distance between the edges of the basic pattern and the related pattern of the substance to be cured is too small, so that the substance to be cured flows over the edge of the basic pattern before and / or during curing.
The decorative base pattern can be printed by means of water-based, solution-based or UV-curable ink, shimmering or matte varnish, color ink, clear or transparent ink or the like.
The substance to be cured can be a photopolymer ink that can be cured afterwards in a curing station, but alternative substances are conceivable. It is also possible that the substance to be cured is formed by printing a liquid or glue on the panel, if possible on top of the decorative basic pattern, after which an intermediate substance is applied to the liquid, so that the intermediate substance forms the substance to be cured or the liquid together form the substance to be cured with the intermediate substance. The intermediate substance is, for example, a thermographic powder or a swelling powder. In the case of a swelling powder, the volume of the substance during melting and / or curing becomes larger than that of the sum of the liquid and the powder separately, so that the increases in the resulting texture become greater during curing. The maximum thickness of the substance after curing can vary between 20 and 1000 micrometres, preferably between 50 and 500 micrometres, and more preferably between 75 and 250 micrometres, but a thinner or thicker texture is conceivable.
In the case that the intermediate substance comprises a thermographic powder, it can be cooled after forced melting of the thermographic powder by forced cooling in order to rapidly increase the viscosity of the molten substance.
In the case that the substance to be cured is formed by printing a liquid or glue on the panel, after which an intermediate substance is applied to the liquid, so that the intermediate substance forms the substance to be cured or the liquid together with the intermediate substance forms the substance to be cured and the intermediate substance comprises a powder, the density of the powder can be increased, for example by pressing, rolling, applying a mixture of different powder sizes, or the like.
The powder can be applied by an electrostatographic process.
In the case that the substance to be cured is formed by printing a liquid or glue on the panel, after which an intermediate substance is applied to the liquid, so that the intermediate substance forms the substance to be cured or the liquid together with the intermediate substance forms the substance to be cured The liquid and / or the substance to be cured may comprise anti-wear particles, anti-scratch particles, pigments, dyes, metallic particles, or the like.
The liquid printed at the second printing substance application step may include a retarder to extend the drying process of the liquid. This can promote the adhesion between the liquid and the intermediate substance before and / or during curing.
Furthermore, the intermediate substance can also be a liquid. In this case, the extended drying properties may be useful to properly mix the liquids.
The liquid that is printed in the second printing substance application step may have priming properties in order to improve adhesion between the panel, the liquid, the intermediate substance and any layer covering the panel on the side where the liquid and the intermediate substance are applied, to improve.
It is advantageous to apply liquids that have a relatively low heat absorption capacity, because this can lead to relatively rapid heating of the intermediate substance absorbed by the liquid. In the case of a powder as an intermediate substance, it will melt quickly. The heat absorption capacity is preferably lower than that of water. The liquid may, for example, contain an alcohol. As a result, a rapid production process can be achieved even when the heat absorption capacity of the panel is relatively high. Furthermore, if the heat capacity of the panel is higher than that of the liquid, the risk of adversely affecting the panel surface below the liquid is minimized.
It is noted that the melting of powders can be carried out efficiently by infrared heating or near infrared curing, since most powders absorb infrared energy very well.
It is possible to concentrate the heat on the liquid and the intermediate substance, or to separately concentrate on the intermediate substance and / or a part of the panel that makes contact with the substance to be cured. In such a case it is possible to choose a liquid and / or an intermediate substance which is compatible with the heat source, such as for example a UV lamp, a UV laser, a lamp that generates optical radiation, a gas discharge lamp, infrared heating, a normal heating or an electron beam heating.
In the first printing step, a displacing means or release means can be printed on the panel and in the second printing step a substance to be cured can be printed on the panel, the displacing means or release means being printed at locations where a flow of the substance to be cured during and / or after the second printing step is hindered or where the substance can be removed after curing. Of course, the first printing step can be preceded by a printing step to print a decoration pattern on the panel. Furthermore, the decoration pattern and the patterns printed at the first and second printing steps may have a predetermined positional relationship to each other.
It is also possible that the intermediate substance is printed at the second printing step, for example a fine powder or a toner that is accurately printed on a liquid cartridge that is printed at the first printing step. It is also possible to print a fine powder or toner directly on the panel during the first and / or second printing step. Experiments have shown that it is advantageous if the fine powder or toner has thermographic properties.
In practice, it is possible that between the first and second printing step at least one intermediate step with regard to applying an additional layer is carried out.
This does not adversely affect the principle of accurately performing the printing steps according to a predetermined positional relationship, because the panel is held at a fixed position relative to the same carrier during the first and second printing step as well as between these steps and any subsequent steps.
The possibility of applying more manufacturing steps than two printing steps in the method according to the invention provides the possibility of obtaining a high production speed and creating numerous possible variations of printing. For example, four print modules can be placed one behind the other and the following combinations can be printed on a passing panel using the cmyk color model: cccc-mmmm-yyyy-kkkk cmyk-cmyk-cmyk-cmyk, or a step-like structure of a textured surface can be created by printing clear ink: clear ink - clear ink - clear ink - clear ink.
In the latter case, the first two modules can include valve jets or tailored print heads that are capable of printing relatively large volumes per passage for a rough but fast texture build-up, because valve jets are less accurate, while the last two modules can include ink jets for a more accurate texture build-up . For example, the valve jets print in 72 dpi, while ink jets with piezo-controlled print heads print in 300 dpi or more. The valve jets or alternative print heads make a base layer and the second series of ink jets make a more accurate layer on top of the base layer. The printing material can be clear or colored ink, matte or glossy, or the like, while intermediate curing can be performed. The number of print modules is not limited to four, but can be two or more.
The number of print modules can be selected in relation to the desired production speed. This is also related to the accuracy of printing. If, for example, printing takes place on the basis of color-in-color, a higher accuracy is required than for printing on the basis of color-on-color.
Furthermore, an increasing speed of the panel relative to the print modules requires a higher and more powerful jet speed, in particular if as a result of the relative speed of the panel and the print module a certain air movement is created at the location of printing. The drop rate can then be increased to 5-7 m / s, preferably 8-9 m / s or even higher. At the same time, the drop volume can be reduced, for example below six picoliters.
It is noted that in the second printing step, different fluid types can be printed before an intermediate substance is applied, the liquids having different absorption properties for receiving the intermediate substance. In this case, the different liquid types can be printed at a third or further printing step before an intermediate substance is applied.
In an alternative embodiment, a substance pattern to be cured for creating a textured surface is printed on the panel in the first printing step, and a decorative pattern is printed on the panel in the second printing step, wherein the substance to be cured is cured in order to cure a textured pattern. to shape. This means that the printing steps for creating a decorative pattern and a textured pattern are reversed with respect to the embodiments described above. The substance to be cured can be cured before or after the second printing step.
In a first example, in the first printing step, a textured layer is printed on the panel, for example by printing a white ink as a substance to be cured. A decorative pattern is then printed at the second printing step, after which a top layer is applied, which comprises, for example, wear-resistant substance and / or anti-wear particles and / or anti-scratch particles. The top layer can be applied by coating, for example by using a roll or a flexible roll, such as a rubber roll.
The first printing step can be preceded by a coating step, for example for pre-coating the panel with a white ink, for example on the entire top surface. In the first printing step, the textured pattern can be constructed in various separate steps by means of successive printing of layers of substance to be cured. In the second printing step, the decorative pattern is printed in a predetermined positional relationship to the textured pattern; for example, a decorative pattern is printed on tops of the textured surface created in the first printing step. However, many other decorative patterns are possible in relation to the textured surface.
In a second example, it is possible to print the top layer by means of a third printing step. For example, one or more digitally controlled print heads can print clear ink on the textured surface. This can create a greater depth effect which is difficult to achieve by, for example, using a roller coating. It is also possible to selectively print the top layer in relation to one or both of the patterns printed in the previous printing steps.
In addition to the last two examples, it is also possible to apply a top layer to the panel after printing a decorative base pattern at the first printing step and printing a substance to be cured at the second printing step to create a textured surface such as described above in various embodiments. In that case it is also possible to apply the top layer to a third printing step by means of roller coating or digital printing. The roll can be textured and / or the panel can be partially coated.
In a further alternative embodiment, the following consecutive steps are conceivable. First, creating a rough base texture surface on a panel by coating the panel by means of a textured roll. A decorative pattern can then be printed on the panel in a first printing step and a substance to be cured can be printed in a second printing step by means of digital printing. The texture created in the second printing step can be finer than the rough base texture.
In general terms, a textured pattern created by printing a substance to be cured can be built up in a number of separate steps by successively printing layers of substance to be cured and, if possible, hardening between the layers. The printed surface can decrease or increase with growing layers, depending on the desired shape of the textured surface. This can be done efficiently by the method according to the invention, since the same basic coordinate set can be used. Furthermore, it is also possible to vary the substance of the substance to be cured per layer, so that a large variation in appearances can be achieved, such as matte, gloss, light, dark, pigmented, etc.
The invention also relates to a device for decorating a panel, comprising a carrier for carrying a panel, a holder for holding the panel at an approximately fixed position relative to the carrier, a decor print module for printing of a decorative pattern on a panel, a texture print module for printing a substance to be cured, a control unit for moving the carrier, the decor print module and the texture print module relative to each other and for controlling the amount of material to be printed by the print modules wherein the control unit is provided with a storage unit for storing coordinates of the pattern which are used to move the carrier, the decor print module and the texture print module relative to each other.
The device does not require a detection system for detecting a pattern on a panel fed to the carrier, nor a separate conversion algorithm for calculating coordinates to control the texture print module based on the pattern printed by the decor print module, because the same reference set coordinates can be used to move the support, the decor print module and the texture print module relative to each other.
In a specific embodiment, the decor print module is part of a stationary decor print station and the texture print module is part of a stationary texture print station, while the carrier comprises an endless conveyor belt along which the print stations are placed. Due to the fact that the panel is transported by the conveyor belt from the decor printing station to the texture printing station and that the stations are arranged one behind the same conveyor belt, a separate alignment station between the printing stations for aligning the panel with respect to the texture print module are omitted. The decor print module can be movable relative to the stationary decor print station and the texture print module can be movable relative to the texture print station. The device can be arranged such that under operating conditions only a single panel is present at the device, and a subsequent panel is not printed at the decor printing station before the preceding panel has left the texture printing station. However, it is also possible that panels are printed synchronously at both print stations.
The tire can have numerous configurations and includes, for example, a drivable chain.
The device may be an actuator for moving the conveyor belt in a lateral direction relative to the conveying direction thereof in order to keep the conveyor belt on a predetermined path. This minimizes discrepancies between the pattern printed by means of the decor print station and the texture print station in the case of corresponding embossing.
The retainer may comprise a vacuum system for pulling a panel toward the conveyor belt. An alternative is that the retainer comprises a clamping system or the like.
In more general terms, the device may include a support for supporting a panel, a retainer for holding the panel at least about a fixed position relative to the support, a first print module, a second print module, a control unit for moving the carrier, the first print module and the second print module to each other and for controlling the amount of material to be printed by the print modules, the control unit being provided with a storage unit for storing coordinates of a pattern used for recording moving the carrier, the first print module and the second print module relative to each other. The device can perform the method described above, wherein the first printing step is performed by the first printing module and the second printing step by the second printing module.
The control unit can adjust the carrier on the basis of one or more sensors for determining the position of the carrier. If the carrier comprises, for example, a conveyor belt, the sensor or sensors can or can monitor an edge of the belt or marks on the surface of the belt. In this way the position of the conveyor belt can be accurately controlled so that a positioning error in the plane of the belt can be smaller than 10 micrometres or even smaller than 5 micrometres.
Because the panel is held at an approximately fixed position relative to the belt, the positioning error of the panel relative to a reference point is also so small.
In the first printing step, a panel to be printed has a fixed position with respect to the carrier. This state can be achieved by determining the current position of the panel relative to the support for the first printing step and correcting it if necessary. Due to the accurate functioning of the carrier, it is not necessary to monitor the position of the panel relative to the carrier during and between the first and second printing steps. If the position of the panel for the first printing step is adjusted relative to the carrier, the coordinates used at the first printing step and the second printing step can be corrected in the same way.
The control unit may have a central control unit with a control algorithm which controls the carrier and the print modules and, if possible, additional modules together, or the device may be provided with two or more separate control units that communicate with each other and / or with control units of further coupled devices for the first print module, after the second print module or between the first and the second print module.
It is noted that the decor print module may be positioned upstream or downstream of the texture print module. Additional print modules and / or surface treatment modules can be placed upstream and / or downstream of the decor print module and the texture print module, for example a roller coating device, a curing device, a third print module or the like.
The invention also relates to a panel decorated according to the method or device described above. The invention also relates to a panel provided with a substrate, a first print pattern on the substrate and a second print pattern on the substrate, wherein the first and second print patterns have a positional relationship. The positional ratio may be such that when the first and second print patterns are superimposed to match as well as possible, the deviation between the patterns is less than 10 microns or even less than 5 microns.
In a specific embodiment, the second print pattern comprises a textured layer that protrudes above the first print pattern. The second print pattern can exactly match the first print pattern, but it can also follow the first print pattern at a predetermined distance or deliberately deviate from the first print pattern. The first print pattern can be a decorative basic pattern, for example a wood imitation pattern, and the second print pattern can provide additional decorative effects, such as an appearance with glitter, mother-of-pearl, silver, gold, gloss, matte or the like.
The panel can also be a continuous sheet.
The panel can be suitable for a floor, wall, ceiling, furniture, packaging or the like, and suitable for indoor and / or outdoor use.
The invention will be explained below with reference to drawings which show embodiments of the invention very schematically.
FIG. 1 is an illustrative view of an embodiment of a device according to the invention.
FIG. 2 is one with FIG. 1 corresponding view of an alternative embodiment.
FIG. 3 is one with FIG. 1 corresponding view of another alternative embodiment.
FIG. 4 is one with FIG. 1 corresponding view of yet another alternative embodiment.
FIG. 5 is a plan view of a portion of an enlarged-scale panel, which panel is made in accordance with the method of the invention.
FIG. 1 shows an embodiment of a device 1 for manufacturing a decorative panel according to the invention. Furthermore, FIG. 1 shows an embodiment of a method for decorating a panel according to the invention. The device 1 is suitable for manufacturing decorative panels in a continuous manner and comprises a loading station 2, a carrier in the form of an endless conveyor belt 3 and a loading station 4. Along the conveyor belt 3 there is a stationary decor printing station 5 and a stationary texture printing station 6. The stationary texture printing station 6 is located downstream of the stationary decor printing station 5.
Under operating conditions of the device 1, panels 7 are supplied from the loading station 2 to the conveyor belt 3. Each of the panels 7 is transported along both printing stations 5, 6. The decor print station 5 comprises a digitally controlled decor print module which prints a decorative basic pattern on the panel 7 that is present on the conveyor belt 3 at the decor print station 5. The texture printing station 6 comprises a digitally controlled texture printing module that prints a substance to be cured on the panel 7. In more general terms, the decor print module is a first print module for performing a first print step and the texture print module is a second print module for performing a second print step. The first print module can be movable relative to the stationary print station 5 and the second print module can be movable relative to the stationary texture print station 6.
After the second printing step, the panel 7 leaves the conveyor belt 3 to the unloading station 4 for further treatment of the panel 7, for example for curing the pattern of the substance to be cured on the panel 7. The device may be provided with vacuum grippers (not shown) for placing the panel 7 from the loading station 2 on the conveyor belt 3 and transferring a panel 7 from the conveyor belt 3 to the unloading station 4, but alternative transfer systems are conceivable.
The device 1 comprises a holder in the form of a vacuum system 8 for pulling the panel 7 towards the conveyor belt 3. As a result, the panel 7 is held in a fixed position on the conveyor belt 3 when the panel 7 passes the printing stations 5, 6 is being fed. In other words, during the step of printing the decorative basic pattern and the step of printing the substance to be cured, as well as between these steps, the panel 7 is held in a fixed position with respect to the conveyor belt 3.
The conveyor belt 3 and the printing modules at the printing stations 5, 6 are controlled by a control unit 9. The conveyor belt 3 in this case is continuously driven, but in an alternative embodiment the conveyor belt 3 can be stopped or slowed down to a lower speed when printing. panel 7 arrives at the corresponding printing stations 5, 6. The control unit 9 is provided with a storage unit with a look-up table which contains coordinates of the decorative basic pattern to be printed on the panel 7 by the decor print module. The same look-up table is used to control the texture print module. As a result, the substance to be cured can be precisely printed on the decorative basic pattern or on parts thereof. In this way, a textured surface with a corresponding relief print can be created. However, this is not necessary; for example, the patterns printed at the first printing step and at the second printing step may be offset relative to each other.
Covering only partially the decorative basic pattern with the substance to be cured can have an advantage for aesthetic reasons. It appears, for example, that in the case of decreasing line thickness in the decorative basic pattern, a more than proportionally smaller amount of substance to be cured on top of the line creates attractive effects, for example in the case that such a line mimics a wood grain.
It is also possible that the second printing step is carried out such that the pattern printed at the second printing step is positioned next to a pattern printed at the first printing step. The decorative basic pattern has, for example, an area that represents a wood grain in which a substance to be cured is printed in addition to the wood grain. This means that the resulting panel has a reduction at the location of the wood grain. It is clear that the method and the device according to the invention, if desired, also provides the opportunity to create an elevation at the location of the wood grain.
With reference to FIG. 1, it is noted that detection means for detecting the coordinates of the decorative basic pattern on the panel 7, such as cameras, have been omitted between the decor printing station 5 and the texture printing station 6. In addition, it is also not necessary to calculate new coordinates for a new look-up table that could be used to control the texture print module. This makes it possible to manufacture decorative panels in a fast-running process, for example at speeds between 0 and 300 meters per minute or higher, if possible depending on the width and length of the belt 3. Experiments have shown that a belt 3 whose top surface has a width of about 1 meter and a length of about 3 meters, can work at a speed of 120 meters per minute to 180 meters per minute, while the length and width accuracy is less than 5 micrometers. The accuracy achieved in a direction perpendicular to the upper surface of the tire 3 is less than 100 micrometers.
In order to keep the relative positions of the panel 7 and the decor printing station 5 on the one hand and the relative positions of the panel 7 and the texture printing station 6 on the other hand, the conveyor belt 3 is controlled such that the panel 7 passes both printing stations 5, 6 at preset or fixed positions relative to a reference point. The device 1 is provided with an actuator (not shown) for adjusting the position of the conveyor belt 3 in a lateral direction with respect to its conveying direction. The device 1 further comprises reversing rollers 10 which guide the endless conveyor belt 3. The deflection rollers 10 are rotatable about shafts whose ends can be moved in a direction transverse to the shafts to compensate for the conical configuration which conveyor belts have in practice. As a result, an at least approximately constant tension across the width of the conveyor belt can be achieved. When thin lines, which represent for example wood grain, are printed on the panel 7 at the decor printing station 5, a substance to be cured can be printed very accurately over the line at the texture printing station 6, or very accurately printed adjacent or near a grain.
If the conveyor belt 3 is driven at a fixed speed, the texture print module can follow the same path as the decor print module, but with a certain time delay.
The delay depends on the speed of the conveyor belt 3.
The speed of the conveyor belt 3 can vary. For example, if a substance to be cured is printed at the second printing station 6 to create a raised surface, the speed of the conveyor belt 3 may be lower at the second printing station 6 than at the first printing station, because a larger amount of the printed matter may be required for printing a basic pattern at the first print station 5. The speed is, for example, 10 m / min when the panel 7 is at the first print station 5 and 2 m / min when the panel 7 is at the second print station 6.
Referring to FIG. 1, it is conceivable to perform additional steps between printing the decorative basic pattern and printing the substance to be cured. For example, it is possible to apply a protective layer to the panel 7, for example a varnish with anti-wear particles. The protective layer is not limited to the decorative basic pattern, but can cover the entire top surface of the panel 7. Subsequently, a substance to be cured can be printed on the panel 7 at the texture printing station 6, if possible after curing or partial curing of the protective layer. Partial curing can have an advantage with regard to adhesion of the different layers. Anti-wear particles can also be added to the substance pattern to be cured. In a specific embodiment, the anti-wear particles in the protective layer can be larger than those used in the substance to be cured. The anti-wear particles in the protective layer can have wear-resistant properties, while the anti-wear particles in the substance to be cured can have scratch-resistant properties.
The decorative base pattern or a textured base pattern can be printed by using water-based or solution-based ink, by means of UV-curable ink, varnish, color ink, transparent ink or the like. The substance to be cured by the texture printing module can be a photopolymer ink or an alternative substance. The medium printed on the panel 7 at the decor printing station 5 may be adapted to the properties of the panel 7, for example the ink absorption properties of the panel 7. Accordingly, the substance printed on the panel 7 at the texture printing station 6 may be adapted to the properties of the medium printed at the decor printing station, for example the ink absorption properties of the substance printed at the texture printing station 6. Furthermore, the viscosity and other properties of the materials to be printed as well as environmental conditions can influence the properties of the pattern to be printed, such as flow behavior of the material on the panel 7. The control unit 9 is provided with a calculation module for calculating the required amount of ink, polymer, etc.
The decor print module and the texture print module can be provided with printheads of the following types, but not limited to these: inkjet printheads, valvejet printheads, piezo controlled printheads, toner based printheads. Furthermore, printing techniques such as silkscreen printing, lithography based printing or laser printing can be applied.
The panels to be printed can be made of various materials, for example MDF, HDF, wood, polymer composite, WPC, LVT, PVC, cardboard, textile, carpet tiles, ceramic, stone, metal or the like. Furthermore, the device 1 can be designed for panels of different shapes and / or dimensions. The products can be suitable for use as floor panels, wall panels, ceiling panels, furniture, packaging, etc. The resulting panels can be large intermediate products that still have to be cut into pieces, after which the pieces can be provided with locking means, such as tongues and grooves. The panel can also be a continuous sheet, which is printed, for example, in a roll-to-roll process.
FIG. 2 shows an alternative embodiment of the device 1. In this case, the device 1 is also provided with one decor printing station 5, but with 3 texture printing stations 6. The texture printing stations 6 build up a substance to be cured in different steps. The substance can be partially or fully cured between the successive texture printing stations 6. Each texture print module is controlled based on the same coordinate lookup table of the decorative basic pattern. It is possible that the amount of substance to be cured that is printed by the texture printing modules is different between the individual texture printing stations 6. For example, in the case of corresponding relief printing, thick lines can be covered by three layers of substance to be cured that are printed by three texture print modules, while thin ones lines can be covered by only two layers of substance to be cured that are printed by two texture print modules. Differences can also be created by changing droplet size, viscosity and other properties.
As described above, it is not necessary that the patterns printed at the printing stations 6 exactly match the decorative basic pattern. The patterns printed at the individual printing stations 6 may even vary. Nevertheless, the device 1 provides the opportunity to create a predetermined positional relationship between the decorative basic pattern and the patterns of the substance to be cured on the basis of a reference coordinate set used at different printing stations 5, 6. The texture printing stations 6 can also print different types of substances in different patterns, for example a gloss substance in a certain pattern and a mat substance in a different pattern.
The decor print module and / or the texture print module can be movable or stationary, depending on the type of patterns to be printed. For example, if a passing panel 7 is to be decorated with a single recessed joint line in the longitudinal direction, i.e. in the direction in which the belt 3 is moved, the decor printing station 5 can print a joint line on the panel and the texture printing station 6 can adhere a substance to be cured print at the joint line, so that the resulting panel 7 is given a floor at the joint line. In such a case, the print modules can be stationary with respect to a reference point.
Furthermore, it is conceivable that the panels 7 pass through a single texture printing station 6 more than once. Referring to FIG. 1, a panel 7, for example, can leave the conveyor belt 3 at the outlet station 4 and be returned to the loading station 2 in order to be supplied once again to the conveyor belt 3. When the decor print station 5 is passed, the decor print module is not activated, but when the texture print station 6 is passed, a subsequent layer is printed on the panel 7 by the texture print module.
FIG. 3 shows an alternative embodiment of the device 1. In this case, the panel 7 is transferred via the unloading station to another conveyor 11. At the first printing station 5 a first print pattern is printed and at the second print station 6 a second print pattern is printed. The second printing station 6 prints a liquid or glue on the panel 7. A powder unit 12 can be controlled to spread a powder over the passing panel 7. Part of the powder sticks to the liquid of the second print cartridge and another part of the powder falls next to the printed substance and will be removed by a suction device 13. This means that the powder sticks to the liquid or glue only at the second print cartridge . If a corresponding relief print is desired, the first and second print patterns coincide. Alternatively, the excess powder can be removed by an air flow, for example by means of an air blade, air knife or air gun. The powder may comprise glitter particles, anti-wear particles such as corundum particles, glass beads, silica or the like. The powder can be a thermographic powder or swelling powder and can be melted into a single mass that protrudes above the initial upper surface of the panel 7.
It is also conceivable that the liquid and powder together form a substance to be cured or that the powder itself forms a substance to be cured which adheres to the panel during curing. In the latter case, the liquid may disappear completely or partially during a curing step, for example due to evaporation.
The thermographic powder can be a thermosetting powder, which contains, for example, a gas-forming agent. The powder grain size can have a predetermined variation and the powder can be pigmented or transparent or the like. An alternative powder can be an ionomer, for example Surlyn. It is advantageous to use an ionomer powder, because it not only forms a textured pattern during curing, but because it also provides anti-wear properties. This means that no additional anti-wear particles are required. Nevertheless, a combination of ionomer powder and anti-wear particles can be used to achieve optimum wear resistance of the textured surface.
In general terms, the invention also relates to a method for manufacturing a panel with a textured surface, comprising the steps of applying a panel, printing a liquid on the panel in a predetermined pattern feeding a powder to be cured to the liquid, curing the powder to form the panel, the powder comprising an ionomer, for example Surlyn. This method can be combined with other steps as described above, for example printing the liquid pattern in a positional relationship with a decorative pattern, removing excess powder, etc. The powder can also comprise anti-wear particles so that after the ionomer has hardened, the particles are embedded in the ionomer layer.
The invention also relates to a method for manufacturing a panel with a textured surface, comprising the steps of feeding a panel, applying a powder to the panel, printing a liquid on the panel with the powder in a predetermined pattern so that the powder is retained at the location of the liquid pattern, removing excess powder and curing the powder or curing the liquid and the powder to form the panel. The powder can comprise an ionomer, for example Surlyn. The powder may also comprise anti-wear particles so that after curing the monomer, the particles are embedded in the ionomer layer. The excess powder removal step can be carried out before or after the curing step.
Various types, shapes and dimensions of the powder are conceivable. For example, metallic resin powder that creates a metallic effect after melting, glossy resin powder in which glossy particles have been added to the powder, antistatic powder that avoids the build-up of electrostatic charge, and powders that create a bead effect, matte effect, or odor effect. The powder may contain release agents such as wax or a gel component to improve the cohesion of the molten polymer.
FIG. 3 shows that the substance to be cured is cured with the powder at a curing station 14, which curing station 14 comprises, for example, a UV lamp, a UV laser, an optical radiation generating lamp, a gas discharge lamp, infrared heating, normal heating or an electron beam heating. Preferably, the curing energy is concentrated on the substance to be cured and / or an adjacent portion of the panel to which the substance is to be adhered. In the case of using UV ink as a liquid for receiving thermographic powder, it is possible to pre-heat the panel and ink to start the melt for starting UV curing. After UV curing, certain thermographic powders are not affected by possible further heat treatments.
It is also possible to control the heating so that the molten substance starts to boil. As a result, an irregular surface will arise that creates an effect of a matte surface. This provides the option of creating a gloss / matte effect on the panel 7.
It is further noted that the powder unit 12, the suction device 13 and the curing station 14 can also be placed along the accurate conveyor belt 3, but this is not necessary because the treatments require less accuracy than the printing steps. In an alternative embodiment, the powder can be added at various consecutive stations, whereby the grain size of the powders can differ between the stations. For example, a powder with a grain size of 150 microns is sprinkled over the panel 7 in a first powder unit and a powder with a grain size of 50 microns in a second powder unit. A combination of different grain sizes of the thermographic powder can increase the packing density of the resulting substance upon curing. Due to the increased density, the powders can melt faster because air inclusions, which typically have insulating properties, are minimized. The resulting molten substance appears to be homogeneous and obtain a smooth surface.
Furthermore, the powder can be pressed into the liquid or glue after sprinkling, for example by means of a roller, a strip, a plate or the like. As a result of pressing the powder into the liquid, the density of the powder increases and improves the adhesion of the powder to the liquid.
It is noted that the liquid printed by the texture printing station 6 may have priming properties to improve the adhesion between the powder and the panel 7 upon curing. In the case of applying an ionomer powder or a panel with a polypropylene surface, an adhesion promoter can be added to the liquid.
FIG. 4 shows an alternative embodiment of the device 1, wherein intermediate steps are performed between printing the decorative basic pattern at the decor printing station 5 and printing the substance to be cured at the texture printing station 6. After the panel 7 has left the decor printing station 5, it comes at a toner printing station 15. A toner is printed on the basis of the same look-up table that was also used for controlling the decor print module at the decor print station 5. Subsequently, the panel 7 is covered with a metallized transfer foil 16 by means of a calander coating system. In the embodiment as shown in FIG. 4, after the curing, the transfer film is rolled up by means of a curing element 17. Subsequently, a next printing step is carried out on the panel 7 at the texture printing station 6. In this case, the decor print station 5, the toner print station 15 and the texture print station 6 are placed along the same accurate conveyor belt 3. They use the same look-up table to control the individual print modules, so that a fast manufacturing process is achieved. Although not shown in FIG. 4, the substance to be cured will be cured after leaving the conveyor belt 3 to form decorative panels. Alternatively, the substance to be cured is formed by printing a liquid at the textural printing station 6 and sprinkling a powder thereon, as described in relation to the embodiment according to FIG. 3. The powder can also comprise anti-wear particles.
The thickness of the substance to be cured or the resulting texture pattern on the panel 7 can vary, but in general the thickness is 5 to 1000 micrometers, preferably between 5 and 500 micrometers or even more preferably between 80 and 250 micrometers. The thickness can also be related to the size of additional particles such as anti-wear particles or pigment particles that are included in the substance to be cured. The width and / or height of the textured pattern in the plane of the panel 7 is preferably greater than the size of anti-wear particles or other particles. In general, it may be undesirable from an aesthetic point of view that particles protrude beyond a boundary of a textured area on the panel 7.
^ Ul U
As mentioned above, the method and the device according to the invention provide the possibility of performing a first and second printing step at a predetermined positional ratio. The carrier or conveyor 3 functions accurately so that the first and second printing steps can be based on the same reference coordinate set without the need to monitor the position of the pattern printed at the first printing step. It has also been described that a substance to be cured can be printed in the second printing step, if possible by first printing a liquid and sprinkling a powder on it. This provides the possibility of creating a textured surface on the panel 7, if possible but not necessarily corresponding to an underlying decorative basic pattern. For example, a panel that mimics a brushed wooden board does not have a fully similar pressure relief pattern. Furthermore, the second printing step can print the same pattern as the first printing step, but at a certain distance therefrom, which is not caused by a lack of accuracy, but intentionally. This is illustrated with reference to FIG. 5.
FIG. 5 shows a part of an upper surface of a panel decorated by the method according to the invention. In the first printing step, a first area 18 with a first edge or contour 19 is printed on the panel 7.
The first region 18 can represent a wood grain of a wooden board and an ink can be used as a print substance. In the second printing step, a second area 20 is printed on the first area 18 and has a second edge or contour 21. The print substance of the second area 20 is a liquid to which thermographic powder 22 is subsequently applied, so that a raised surface is positioned at the first area 18 is created.
It may be desirable in practice to keep the first contour 19 clearly visible after finishing the panel 7. If the second region 20 overlaps the first contour 19, this could lead to a vague first contour 19, even if the substance of the resulting second region 20 is transparent. To prevent the fluid from the second region 20 from flowing over the contour of the first region 18, the coordinates used for the first printing step are adjusted such that the fluid from the second region 20 within the first region 18 at a certain distance is printed from the first contour 19 of the first area 18. The distance to be selected depends on the viscosity of the liquid of the second region 20. Furthermore, the distance depends on the particle size of the powder 22.
FIG. 5 illustrates that particles can project beyond the second contour 21 of the second region 20, but remain within the first contour 19 of the first region 18. The distance between the contours 19, 21 of both regions 18, 20 should therefore be such that particles adhering to the edge of the second region 21 do not, after curing, extend over the edge of the first region 18. In the case of using a swelling powder, the distance between the two contours 19, 21 can be even higher. When an extremely small particle size powder is applied, any protrusion of particles outside the second contour 19 is minimized and the distance between the first and second contour 19, 21 can be minimized.
The powder 22 can be supplied relatively inaccurately by spreading it over the panel 7 and removing the excess hardening powder 22, but it is also possible to accurately print the powder at the second region 20 in a third printing step, for example by using a toner-based printer module. Alternatively, the powder 22 may be supplied by an electrostatographic process, such as xerography, ionography, laser printer technology, or the like.
If it is desired to create a higher surface level outside the first area 18, the second printing step should print a liquid outside the first contour 19 of the first area 18. In that case, the coordinates used in the first printing step can easily be adjusted to perform the second printing step so that printing of the liquid stops at a predetermined distance from the first contour 19 outside the first region 18.
Although the embodiment of FIG. 5 illustrates a second printing step that is followed by sprinkling or printing thermographic powder 22, it is also conceivable that a substance to be cured is printed at the location of the second region 20 without the need for adding a powder afterwards.
Furthermore, it is about flowing over pattern edges as illustrated in FIG. 5, it is also possible to print a displacing agent or release agent. Referring to FIG. 5, it is again possible to print the first area 18 at the first printing step. In the second printing step, a displacing means or release means can be accurately printed on the first contour 19 and possibly also within the first contour 19, whereafter in a third printing step a substance to be cured can be printed outside the first region 18. The displacement substance at the location of the first contour 19 prevents the substance to be cured or the melting thermographic powder from flowing over the first contour 19 to the first region 18. Afterwards, the displacement means can be removed or remain on the panel 7. The displacing agent can be made from silicone. If the displacing means or release means is subsequently removed, it is permissible to also print the substance to be cured within the first region 18 in the third printing step, so that less accurate printing of the substance to be cured is possible. With the method and the device according to the invention, numerous variations of the processes are possible due to the possibility of accurate printing without temporarily monitoring the relative position of any pattern on the panel 7.
Flowing over pattern edges during curing can also be avoided by manipulating the curing conditions, for example by rapid cooling after melting of thermographic powder to rapidly increase the viscosity of the molten substance.
Instead of simulating a wood grain as described above, it is possible to create a textured surface on a panel in the form of oblique side edges to create a V-groove between adjacent panels. Such a texture can be created, for example, by printing a number of layers of liquid or glue on each other, which layers become narrower in a direction away from the panel, while a thermographic powder is sprinkled over the layers. After the resulting substance has hardened, a panel is formed with obliquely opposite side edges. Of course, numerous alternative print edges are conceivable in order to achieve the same result.
The manufacturing method of the present invention further provides the ability to create different print layers that are adjacent to or adjacent to each other instead of or in addition to printing layers on top of each other, for example, to create areas with different gloss levels. Nevertheless, the method according to the invention can be used to make a texture surface with varying gloss levels.
Furthermore, it is possible to print liquids of different properties on a panel by means of a number of print modules. The liquids can vary, for example, in the degree of powder acceptance, so that after spraying a thermographic powder and removing excess powder, different powder densities are present on the panel. After hardening of the resulting substance, the texture will vary in height direction.
The degree of powder acceptance can also be influenced by the liquid absorption capacity of the panel. If the liquid is absorbed quickly, it will absorb less powder, resulting in a relatively low increase.
In another additional manufacturing step, a finishing layer can be applied to the panel, for example, a layer containing wear-resistant particles.
It will be clear from the foregoing that the invention provides an efficient method for decorating panels and a device therefor.
Due to the accurate functioning of the carrier, it is possible to accurately repeat various printing steps and to create numerous variations of possible successive process steps. For example, it is possible to manufacture a panel that mimics a wood grain that is lower and shinier with respect to its surrounding surface. The following process can be performed. First print a wood grain pattern of liquid on the panel, then spread a glitter powder on the liquid and then remove the excess glitter powder. Then print a second liquid cartridge outside and adjacent to the wood grain pattern, spread a matte powder with thermographic properties on the second pattern and remove the excess matte powder. After melting and / or curing the liquids and / or powders, the panel surface outside the wood grain will be higher and have a matte appearance, while the lower wood grain will have a glossy appearance.
The invention is not limited to the embodiments described above as shown in the drawings, which can vary in various ways without departing from the scope of the invention. The variations of printing, in particular related to thermography, can be applied in a separate manner, independent of the method that has at least two printing steps and uses a different device than described above.

权利要求:
Claims (15)
[1]
Conclusions
A method for decorating a panel (7), comprising the steps of feeding a panel (7) to a carrier (3), performing at least a first printing step by means of a first printing module and performing a second printing step by means of a second printing module, wherein the first and second printing steps are performed in a predetermined positional relationship to form the decorated panel (7), and wherein during and between the first and second printing steps the panel (7 ) is held at an approximately fixed position relative to the carrier (3).
[2]
A method according to claim 1, wherein the carrier (3) has preset positions relative to a reference point during the first and second printing steps.
[3]
A method according to claim 2, wherein during the first and second printing steps the carrier follows preset paths relative to the reference point.
[4]
A method according to claim 3, wherein the preset paths extend at least one behind the other.
[5]
A method according to any one of the preceding claims, wherein in the first printing step a decorative basic pattern is printed on the panel (7) and in the second printing step a substance to be cured is printed on the panel (7), whereafter the substance to be cured is hardened.
[6]
A method according to claim 5, wherein the substance to be cured is printed over at least a part of the decorative basic pattern or adjacent to the decorative basic pattern.
[7]
A method according to any one of the preceding claims, wherein at least one intermediate step for applying an additional layer to the panel (7) is performed between the first and second printing step.
[8]
A method according to any one of the preceding claims, wherein the carrier (3) has fixed positions with respect to a reference point during the first and second printing step.
[9]
A device (1) for manufacturing a decorative panel, comprising a support (3) for supporting a panel (7), a holder (8) for holding the panel (3) on an at least approximately fixed position relative to the support (3), a decor print module for printing a decorative pattern on a panel (7), a texture print module for printing a substance to be cured, a control unit (9) for moving relative to each other the carrier (3), the decor print module and the texture print module and for controlling the amount of print material through the print modules, the control unit (9) being provided with a storage unit for storing coordinates of the pattern which are used for moving the carrier (3), the decor print module and the texture print module apart.
[10]
A device according to claim 9, wherein the decor print module is part of a stationary decor print station (5) and the texture print module is part of a stationary texture print station (6), while the carrier comprises an endless conveyor belt (3), along which the print stations (5, 6).
[11]
A method according to claim 10, wherein the retainer comprises a vacuum system (8) for pulling a panel (7) towards the conveyor belt (3).
[12]
A device according to claim 10 or 11, wherein the device (1) is an actuator for moving the conveyor belt (3) in a lateral direction relative to the conveying direction thereof in order to keep the conveyor belt (3) in a predetermined path .
[13]
A device according to any of claims 9-12 wherein a curing station (14) is present upstream or downstream of the texture printing module.
[14]
A device according to claim 13, wherein a powder unit (12) for spreading a powder over a passing panel (7) is present between the texture printing module and the curing station (14).
[15]
A device according to claim 9, wherein the decor print module comprises a print head for printing a liquid and the texture print module comprises a print head for printing a powder.

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同族专利:

公开号 | 公开日

PL3492274T3|2021-06-14|

EP3290226B1|2019-01-02|

CN104768771A|2015-07-08|

ES2847410T3|2021-08-03|

RU2635965C2|2017-11-17|

PT3290226T|2019-03-21|

EP3492274A1|2019-06-05|

EP2708375B1|2017-11-22|

US20220032606A1|2022-02-03|

CN110370849B|2021-06-22|

EP3492274B1|2020-11-04|

CA2884285A1|2014-03-20|

CN110370849A|2019-10-25|

EP3290226A1|2018-03-07|

ES2718079T3|2019-06-27|

CN104768771B|2019-07-30|

ES2656335T3|2018-02-26|

BR112015005296A2|2017-07-04|

WO2014041085A1|2014-03-20|

PL3290226T3|2019-07-31|

US20150239230A1|2015-08-27|

EP2708375A1|2014-03-19|

RU2015110638A|2016-11-10|

CA2884285C|2021-05-25|

TR201802141T4|2018-03-21|

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法律状态:
2021-09-30| PD| Change of ownership|Owner name: FLOORING INDUSTRIES LIMITED, SARL; LU Free format text: DETAILS ASSIGNMENT: CHANGE OF OWNER(S), CHANGE OF LEGAL ENTITY; FORMER OWNER NAME: UNILIN, BV Effective date: 20210723 |

优先权:

申请号 | 申请日 | 专利标题

EP12184516.8A|EP2708375B1|2012-09-14|2012-09-14|A method and an apparatus for decorating a panel|

EP121845168|2012-09-14|

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