• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of manufacturing a panel (1) comprises the steps of supplying a substrate (4, 9), applying an agent (7) to be sublimated on at least one side of the substrate (4, 9). ), supplying a recording layer (3) for receiving the agent to be sublimated (7) in the sublimation, bonding the substrate (4, 9) and the recording layer (3) together, and sublimating the substrate (4, 9) together. sublimating means (7) towards the recording layer (3) to form a panel (1) provided with the substrate (4, 9) and the recording layer (3) with the means to be sublimated (7). The agent (7) to be sublimated is applied directly to the substrate (4, 9) as a separate substance.
    公开号:BE1021491B1
    申请号:E2012/0794
    申请日:2012-11-21
    公开日:2015-12-02
    发明作者:Bruno Paul Louis Vermeulen
    申请人:Spanolux Nv-Div Balterio；
    IPC主号:
    专利说明:

    METHOD FOR MANUFACTURING A PANEL
    The present invention relates to a method for manufacturing a panel comprising the steps of applying a substrate, applying a sublimable agent to at least one side of the substrate, applying a recording layer for recording of the sublimating means upon sublimating, securing the substrate and the recording layer together, and sublimating the sublimating means to the recording layer to form a panel provided with the substrate and the recording layer with the sublimating means.
    Such a method is known in the prior art. In the known method, the substrate is attached to the recording layer before the agent to be sublimated is attached to the substrate. The means to be sublimated is carried by a transfer sheet and applied to the substrate by placing the transfer sheet on the substrate at its side over the layer attached to the recording layer ---------- ----- side is located. The transfer sheet is then heated such that the means to be sublimated sublimates to the recording layer. This means that the agent to be sublimated evaporates and penetrates through the substrate into the recording layer. After the sublimation process, the transfer sheet can be removed from the substrate.
    An object of the invention is to provide an efficient method for manufacturing a panel.
    This is achieved with the method according to the invention, wherein the agent to be sublimated is applied directly to the substrate as a separate substance.
    An advantage of the method according to the invention is that a transfer sheet can be omitted. It is noted that the steps of the method according to the invention are not necessarily performed chronologically. Certain steps can be performed in reverse order to the order described above. Furthermore, certain steps can be performed simultaneously, or additional steps or intermediate steps can be performed. "
    The agent to be sublimated can be applied in the form of a decorative pattern. During the sublimation step, the pattern of the means to be sublimated is transferred to the recording layer. Numerous patterns are conceivable, for example wood patterns, stone patterns, or the like, if possible with varying colors. A sublimation process appears to result in attractive decoration patterns in the resulting panel, because any non-regular pattern of the agent to be sublimated on the substrate, for example due to an error in the process of applying the agent to be sublimated, during the step involving until the sublimation will be settled. This is caused by the fact that the means to be sublimated slightly diverges during the movement thereof at the sublimation step. If the agent to be sublimated is applied by means of a controlled nozzle, a failed nozzle may create a disturbed pattern of the agent to be sublimated on the substrate, but the disturbance may have disappeared after sublimation.
    The agent to be sublimated may be a water-based, solution-based agent or a material containing a UV-curable agent. The water-based agent has an advantage from the cost point of view of the agent as well as with regard to the technology required for applying it to the substrate. The solution-based agent is advantageous for adhering to certain materials of the substrate, for example substrates made from a polymer, for example acrylate, PVC, or the like. The agent to be sublimated can be a sublimable colorant (ink or dye) that comprises a resin binder and a dye which is generally referred to as a disperse dye. The disperse dye may be an organic dye such as disazo dyes, anthraquinone dyes, and methine dyes.
    The resulting panel can be rigid or flexible and can be an end product or an intermediate product. The resulting panel can be, for example, a foil that still needs to be attached to a rigid layer by means of laminating, gluing or the like. The film can for example be rolled up and transported or stored. In the case where the substrate and the recording layer are already attached to each other before the means to be sublimated is applied, the resulting panel may be a large board which must be sawn into separate pieces after the sublimation step. In such a case, the supplied substrate and the recording layer may already be attached to one or more layers to form a rigid board before the means to be sublimated is applied. The separate pieces can be provided with locking means such as tongues and grooves in order to fix the pieces together, as is known from floor panels according to the prior art. Alternatively, the resulting panels may already be provided with locking means and be ready for use after the sublimation step. In such a case, the supplied substrate and the recording layer may already be attached to one or more layers and be provided with locking means before the means to be sublimated is applied; the substrate cart: ----------- smaller than the aforementioned board.
    The resulting panel can be a floor panel, a wall panel, a ceiling panel, a panel for furniture, packaging, baseboards or the like and suitable for indoor and / or outdoor use. It can be made of wood-based material such as MDF, HDF, WPC, or vinyl, metal, glass, stone, ceramic, polymer composite or the like.
    The resulting panel comprises at least the substrate and the recording layer, but it can also comprise one or more additional layers, for example a core, the recording layer being enclosed between the substrate and the core. The supplied substrate can thus already be attached to other layers before the agent to be sublimated is applied.
    The recording layer may be provided with a film or film, a resin-impregnated sheet, for example a resin-impregnated paper or non-woven sheet or material, a UV lacquer layer, a water-based or solution-based lacquer layer. The recording layer may have absorption properties for absorbing the agent to be sublimated. However, it is also possible for the agent to be sublimated to penetrate through the substrate and stop at the surface of the recording layer so that the sublimated agent will be partially or completely present on the recording layer. The properties are preferably such that spreading of the agent to be sublimated in the lateral direction of the displacement trace to and / or in the recording layer is minimal. The recording layer can form a white background before the agent to be sublimated is applied. Because the recording layer can be applied to produce panels with different decorative patterns, it can be used in large quantities, reducing costs.
    The recording layer can be attached to a core that is at least approximately impervious to the agent to be sublimated. This means that the sublimable agent does not penetrate into the core after the sublimation step, for example in the case of a recording layer that absorbs the sublimated agent. ------------ The sublimation step can - be - carried out by means of ------------- supplying heat so that the agent to be sublimated evaporates. It is conceivable to concentrate the heat on the agent to be sublimated, but in an alternative embodiment the substrate and / or the recording layer are also heated. During the sublimation step, the substrate can be covered with the means to be sublimated by means of a cover member to force the means to be sublimated to go from the cover member to the recording layer. The cover member may comprise a sheet or a plate which can be heated. Moreover, the cover member can exert a pressure on the substrate during the sublimation step. The cover member may comprise a heated press plate with a textured surface or a heated textured press roll or a relatively thin textured release layer on a flat heated press plate so that the sublimation step is combined with a step with respect to pressing the substrate, if possible in accordance with the substrate. pattern of the agent to be sublimated, for example a wood grain pattern. The embossing-in-register can be performed more precisely in this case than in conventional lamination processes in which a resin-impregnated paper sheet is provided with a decorative pattern, because the position of the pattern on the paper sheet as a result of the impregnation varies in practice. Furthermore, the sublimation step can be combined with a lamination step by using a heated pressing plate, and if possible also combined with impression.
    The heat can be concentrated on the agent to be sublimated, for example by applying laser technology. Furthermore, it is conceivable to use the laser technology to also create a textured surface of the panel. The substrate can also have a textured surface before the agent to be sublimated is applied. In that case, the agent to be sublimated can be printed in accordance with the textured surface such that the resulting panel obtains a corresponding relief print with the agent to be sublimated.
    It is noted that in the case of hot pressing during the sublimation step, it is possible to apply a release layer between a pressing plate and the substrate with the sublimating means to facilitate releasing the pressing plate and the resulting product after hot pressing.
    The method according to the invention is also advantageous in cases where a substrate surface has limited adhesion properties for inks or dyes, for example substrates made from particular polymers.
    Conventionally, such surfaces must be pretreated by means of a primer, corona treatment, plasma treatment or the like before an ink or dye is printed thereon to sufficiently bond the ink or dye to the substrate. Because the method according to the invention moves the agent to be sublimated away from the substrate surface, the requirements with regard to the adhesion properties are limited. Therefore, pretreatments of the substrate surface can be minimized. For example, it is known that direct application of a particular agent to be sublimated to a surface of a polypropylene sheet can be difficult. In such a case, a top layer can be applied to the polypropylene sheet, after which the agent to be sublimated is applied to the top layer. During the sublimation step, the agent to be sublimated is transferred to the polypropylene sheet such that the sublimated agent is trapped between the polypropylene sheet and the top layer.
    In this case, the substrate is formed by the top layer, and the recording layer is formed by the polypropylene sheet. In the sublimation step, the agent to be sublimated penetrates the substrate and passes to the recording layer. In this case, but also in general, the recording layer can record the sublimated agent without absorbing the sublimated agent in the recording layer. In addition, the sublimated agent may remain partially in the substrate after the sublimation step. In the above example, the method according to the invention provides the opportunity to apply a decorative pattern to the polypropylene sheet without the typical printing and conventional adhesion problems of ink or the like to the polypropylene sheet.
    The substrate can be provided with an adhesive material to temporarily adhere the agent to be sublimated to the substrate, i.e., in the period between the step of applying the agent to be sublimated to the substrate and the sublimation step. In practice, the agent to be sublimated and the substrate will be selected based on their mutual compatibility. The substrate preferably comprises a print-receptive coating, for example an ink-receptive coating, which is suitable for receiving a sublimable agent, for example a water-based or solution-based ink or a material comprising UV-curable ink. The agent to be sublimated may have viscosity and drying properties such that the flow of the agent to be sublimated onto the substrate is limited and that it dries quickly after being applied to the substrate.
    Furthermore, conventional process steps such as printing a decorative pattern on a paper sheet, impregnating the paper sheet with a resin and laminating the impregnated paper sheet on a core can be omitted.
    Another advantage of the method according to the invention is that a balance layer can be omitted. Conventional laminates that have a resin-impregnated paper sheet as a decorative layer on top of a core require a balance layer at the bottom of the core. The omission of a resin impregnated decorative sheet means that a balance layer can be omitted or made relatively thin.
    In a preferred embodiment, the agent to be sublimated is printed on the substrate by a digital printer. The use of a digital printer provides a high degree of flexibility in the pattern to be printed. This makes the production of relatively small product sizes with different decoration patterns efficient. Production series can be made unique and / or customer-specific and outdated stocks can be avoided. Alternative embodiments of contact printing or non-contact printing of the means to be sublimated are conceivable, for example by means of roll coating. When the agent to be sublimated is printed on the substrate, it can have a speed of 5 to 10 m / s, but a higher or lower speed is conceivable.
    The side of the substrate to which the agent to be sublimated is applied may have a textured surface, or, for example, grooves, sloping edges, or the like. It is possible that the substrate is already provided with a textured surface before the substrate and the recording layer are connected to each other.
    The substrate and the recording layer can be attached to each other for applying the agent to be sublimated. In this case, the substrate and the recording layer are supplied as one whole unit, after which the agent to be sublimated is applied to the substrate. The unit may be an intermediate panel comprising a plurality of layers, e.g., the substrate, the recording layer, and a core with the recording layer sandwiched between the substrate and the core. The core can be at least approximately impermeable to the agent to be sublimated. This means that during the sublimation step the agent to be sublimated penetrates the substrate and, if possible, the recording layer, if it absorbs the sublimated agent, but the sublimated agent does not go beyond the recording layer. The core can be rigid or flexible such that the resulting panel is rigid or flexible. It can be made of wood-based material such as MDF, HDF, WPC, or vinyl, metal, glass, stone, ceramic, textile, non-woven material, polymer composite or the like. As described above, the resulting panel may be ready for use or require further treatment, e.g., cutting into pieces, providing locking means and the like, and if possible other post-treatments such as applying additional layers or the like.
    The substrate can comprise a protective layer with anti-wear particles. This means that the unit of the substrate and the recording layer can be prepared as an intermediate panel which is already provided with anti-wear properties, but which does not yet have a decorative pattern. The recording layer may, for example, be a white layer or include a background color. During the sublimation step, the agent to be sublimated can be transported through the protective layer and penetrate into the recording layer or remain at least approximately between the protective layer and the recording layer. The anti-wear particles can be corundum particles, glass beads, silica or the like. The size of the particles can be chosen such that their influence on the sublimation process is minimized. In an alternative embodiment, the protective layer comprises, for example, an ionomer such as abcite or Surlyn ™. A combination of an ionomer and particles is also conceivable.
    In an alternative embodiment, a further layer is applied to the substrate after applying the agent to be sublimated. The substrate may comprise an intermediate protective layer, which is primarily intended to protect the intermediate panel during storage between the step of securing the substrate and the recording layer and the step of applying the agent to be sublimated. In addition, after applying the further layer to the substrate and after the sublimation step, the agent to be sublimated will be present at a greater distance from the outer surface of the resulting panel than in the case of omitting the further layer. It is noted that more than one further layer can be applied. Each further layer can have different properties, for example with anti-scratch properties, UV resistance, color stability, and the like.
    The substrate may comprise an intermediate protective layer and the further layer may comprise a protective layer with anti-wear particles. The intermediate protective layer can also have anti-wear particles. In this case, the size of the particles in the protective layer may differ from the size of the particles in the intermediate protective layer. The particles in the intermediate protective layer can, for example, be smaller than the particles in the protective layer. The intermediate protective layer is a transparent layer in order to keep the recording layer visible.
    The protective layer and / or the intermediate protective layer can be made from Resins such as melamine, melamine mixtures, phenol, polyester, ionomers, polyurethane, acrylate, or the like. In more general terms, the substrate and / or the recording layer and / or any further layers may comprise resins such as melamine, melamine blends, phenol, polyester, ionomers, polyurethane, acrylate, or the like. The resins can be impregnated into a sheet, such as a paper sheet or the like. In particular, a polyester-containing layer appears to have an advantage because it has good sublimation characteristics and is suitable for a lamination process. Of course, the polyester-comprising layer can be a mixture of polyester and other acrylates or resins.
    It is generally noted that resin layers through which a sublimated agent must pass can be partially cured, because a fully cured resin layer can impede the transport of the sublimated agent to the recording layer. During or after sublimation, the curing process can be terminated to attach the sublimated agent to the resin-containing layer
    The substrate and the further layer can be attached to each other synchronously with the sublimation step. The further layer may comprise, for example, a resin-impregnated overlay sheet which is fixed to the substrate by means of hot pressing, under which circumstances the sublimation step also takes place. This is in fact a combination of a lamination process and a sublimation process. In addition, more than one further layer can be laminated during this process. It is also possible to combine lamination and sublimation with pressing the further layer, for example by using a heated press plate with a textured surface or a heated textured press roll. The pressing is possibly performed in accordance with the pattern of the means to be sublimated, for example a wood grain pattern or the like.
    It is also possible to combine the lamination and impression process while the sublimation step is performed afterwards.
    Alternatively, it is possible to combine the step with respect to the substrate and the substrate with respect to the substrate and the step with regard to pressing, while the sublimation step is carried out afterwards. In the latter case, the substrate can be textured by means of, for example, a textured roller, which roller simultaneously applies the ink to be sublimated to the surface.
    In an alternative embodiment, the substrate and the recording layer are attached to each other after applying the agent to be sublimated. In this case, the agent to be sublimated is first applied to the substrate and then the substrate is attached to the recording layer with the agent to be sublimated. In fact, the substrate with the agent to be sublimated can be compared to a conventional transfer sheet with a agent to be sublimated, but in this case the substrate is attached to the recording layer while the conventional transfer sheet is removed after the sublimation step. It is noted that the recording layer may be part of an intermediate panel comprising a recording layer, a core and possibly a balance layer and / or further layers. Depending on the side of the substrate on which the means to be sublimated is printed and the side of the substrate that faces the recording layer, the means to be sublimated can move through the substrate when moving to the recording layer.
    It is advantageous to perform the step of securing the substrate and the recording layer and the sublimation step synchronously, as this provides a fast manufacturing process.
    The step of fixing and the sublimation step can be carried out in a lamination process at elevated temperature and pressure, i.e. by hot pressing. The substrate comprises, for example, a resin-impregnated paper sheet or non-woven material on which an agent to be sublimated is printed. The resin-impregnated sheet may be dry, but the resin is not yet fully cured; the sheet can be in the so-called b-stage. The sheet is positioned on a recording layer and the stack of the recording layer and the impregnated sheet are placed in a heated press ~ t ~ ~ ._Ti] "during" the "t" heat pressing ~ melting ~ resin ~ ^ "Etr will flow to the recording layer, while the agent to be sublimated will evaporate and go to the recording layer and possibly penetrate into the recording layer. Printing on a resin-impregnated sheet, for example a paper sheet impregnated with polyester, or a resin blend of melamine and polyester, or the like, has an advantage in that the absorption rate is limited and a resin is suitable for incorporating numerous inks or dyes to be sublimated In an alternative embodiment, the substrate comprises a sheet on which the agent to be sublimated is printed before resin in the In the latter case, the substrate can be partially cured, for example by means of near infrared radiation to prevent premature sublimation of the substrate. to avoid a bleaching agent and to create a smoother surface than when using conventional drying processes, which creates a more printable surface. During the impregnation, the curing process is controlled in such a way that the sheet is not fully cured during the impregnation process. In accordance with what has been described above, the sublimation step can be carried out simultaneously with attaching the resin-impregnated sheet to the recording layer.
    Furthermore, the substrate can be provided with anti-wear particles. For example, in the case of a resin-impregnated sheet, the resin may contain anti-wear particles.
    In addition, in the same lamination process, one or more layers can be laminated onto the substrate and the recording layer as with conventional lamination techniques, for example in the field of laminated floor panels.
    Furthermore, the protective layer or any further layer positioned on top of the resulting panel can be provided with a textured surface during the lamination process. In the case of printing in accordance with a pattern, it may be an advantage if the resin-impregnated sheet on which the agent to be sublimated is printed is impregnated before the printing step occurs because expansion of the sheet due to impregnation in "that ^ case ^ already "h ^ f1: _piLaafrsg-ëvbndëTï," zociatr and a better alignment is possible between the sublimated pattern and the textured pressing member.
    Preferably, the side of the substrate on which the means to be sublimated is applied faces the recording layer, because during the sublimation step the means to be sublimated can penetrate directly into the recording layer instead of first passing through the substrate. In the case of a lamination process, the agent to be sublimated is applied to the substrate and the substrate can then be turned over and positioned on the recording layer. The lamination process and the sublimation process can be set so that the sublimation process proceeds faster to prevent the flow of the resin from adversely affecting the sublimation process.
    It is also possible to provide anti-wear particles on the side of the substrate facing the recording layer in order to reduce the risk of damage to the pressing member during the lamination process. On the other hand, the anti-wear particles can be provided on the opposite side of the substrate in order to prevent the agent from being impeded by the particles during sublimation. It is also possible to apply the anti-wear particles on opposite sides of the substrate.
    When the substrate or any further layer comprises a resin-impregnated sheet, a relatively thin balance sheet can be used. It is even possible to omit the balance sheet or replace it with a lacquer layer or the like.
    In an alternative embodiment, the substrate can receive and retain sublimated agent. In this case, the agent to be sublimated that is printed directly on the substrate as a separate substance will be sublimated into the substrate and go to the recording layer, but will not or partially reach the recording layer. Depending on the sublimation process, the agent to be sublimated can penetrate into the recording layer attached to the substrate. In this case, the substrate and the recording layer can together form an integrated recording layer.
    In general terms, the invention also relates to a "get lost" of "a panel 7" and to the steps of supplying a substrate provided with a recording layer for recording. a sublimable means, applying a sublimable means to at least one side of the substrate, sublimating the means to sublimate into the recording layer to form a panel, the means to be sublimated as a separate layer directly onto the substrate The resulting panel may be a flexible or rigid panel, but may be provided with additional layers to support or cover the substrate.The substrate may comprise, for example, a PET film, for example, with a thickness of 300 μιη or thinner or thicker: during sublimation, the agent to be sublimated penetrates into the substrate, which substrate may be connected to a background layer.
    Further, in this embodiment, other features as described above can also be applied in relation to the embodiments, such as a textured surface on the substrate, synchronous pressing and / or sublimation and / or lamination etc.
    For example, the substrate forms a top layer of a core made of composite polymer, such as WPC or the like.
    The substrate or top layer comprises a recording layer and the agent to be sublimated is applied to the side of the substrate remote from the core. In the sublimation step, the agent to be sublimated will penetrate into the top layer. Between the core and the top layer a layer may be present which has a contrasting color, for example white.
    The lamination processes mentioned in this document can be carried out by means of a continuous press or a non-continuous press. In addition, the press can be provided with a textured press member in order to also combine pressing with lamination and / or sublimation.
    The invention will be explained below with reference to drawings which show embodiments of the invention in a very schematic way.
    FIG. 1-6 are illustrative views of successive steps of an embodiment of the manufacturing method of a panel according to the invention. _
    Fi.g. 7-12 are with FIG. 1-6 corresponding views showing an alternative embodiment.
    FIG. 13-16 are with FIG. 1-6 corresponding views showing another alternative embodiment.
    FIG. 17-19 are with FIG. 1-6 corresponding views showing yet another embodiment.
    FIG. 21 is an illustrative view of successive steps of an embodiment of the method according to the invention.
    FIG. 1-6 show successive steps of an embodiment of a method for manufacturing a panel according to the invention. FIG. 1 shows an intermediate panel provided with the following layers: a core 2, a base coating 3, a protective layer 4 and a balance layer 5. The layers 2-5 are attached to each other, for example by means of continuous or non-continuous pressing, laminating , calendering, coating, extruding or the like. In the embodiment as shown, the substrate according to the invention comprises the protective layer 4 and is provided with anti-wear particles, for example corundum, glass beads, silica or the like. The substrate or the protective layer 4 is the top layer of the intermediate panel. FIG. 1 also shows a digital printer 6 with a number of print heads. The digital printer 6 can print a means 7 to be sublimated on an upper side of the protective layer 4. The agent 7 to be sublimated can be printed according to any desired decorative pattern. In FIG. 2, the resulting state of the layers 2-5 after printing is illustrated. It is noted that the balance layer 5 can be omitted if the core 2 is sufficiently rigid, because the intermediate panel does not comprise a resin-impregnated decorative paper such as prior art laminates. The material of the core 2 can be a wood-based material such as MDF, HDF, WPC, or vinyl, metal, glass, stone, ceramic, polymer composite or the like.
    FIG. 3 and 4 illustrate process steps in which a heating plate 8 is moved to the top of the protective layer 4 and touches the top of the protective layer 4. The heating plate 8 can be pressed onto the intermediate panel to realize a good contact between the heating plate 8 and the protective layer 4. FIG. 5 shows a state in which the heating plate 8 heats and evaporates the agent 7 to be sublimated. The base coating 3 comprises a recording layer for recording the sublimating means 7 when sublimating. As a result of the material properties of the agent 7 to be sublimated and the base coating 3, the evaporated agent 7 penetrates the protective layer 4 into the base coating 3. A resulting panel 1 comprising the protective layer 4, the base coating 3 with the sublimated agent 7, the core 2 and the balance layer 5 is shown in FIG. 6. The surface of the sublimated agent can be larger than the surface of the agent to be sublimated because the agent to be sublimated slightly diverges during the sublimation step.
    In the embodiment of the intermediate panel as shown in FIG. 1-5, the protective layer 4 makes it possible for the agent 7 to be sublimated to pass through, and the core 2 avoids penetration of the agent 7 to be sublimated. As a result, the agent 7 to be sublimated remains sublimated to the core 2. the base coating 3. Alternatively, the base coating 3 may be impermeable to the agent 7 to be sublimated so that the agent 7 to be sublimated does not penetrate into the base coating but remains on its surface, substantially between the base coating 3 and the substrate 4. In a In such a case, the agent to be sublimated goes to the base coating 3 but is not absorbed thereby.
    A significant time difference may exist between the time of manufacturing the unit of the layers 2-5, i.e., the intermediate panel, as shown in FIG. 1 and the step of printing the means to be sublimated 7, as illustrated in FIG. 1. The unit of the layers 2-5 can be stored before the agent 7 to be sublimated is applied to the protective layer 4. This means that stored intermediate panels can be ready for use, but that they do not yet have a decorative pattern. During the sublimation step, the decorative pattern is applied without at least substantially influencing other properties of the panel 1. In other words, the protective layer 4 retains its protective properties when "decorating" the intermediate panel.
    An advantage of the method as illustrated in FIG. 1-6 is that the means 7 to be sublimated is printed as a separate substance directly on the intermediate panel. This means that additional steps with regard to first printing the sublimable means on a transfer sheet and with regard to removing the transfer sheet from the resulting panel 1 after the sublimation step, as is carried out in the prior art, can be omitted.
    The protective layer 4 can have various functions such as wear resistance, acoustic properties, antistatic properties, creation of light stability, etc. The material is also selected on the basis of the recording properties thereof in terms of temporarily attaching the agent to be sublimated after the printing step.
    Furthermore, the protective layer 4 for the printing step can have a textured surface or it can be pressed in afterwards, for example during the sublimation step. In the latter case, the protective layer 4 may comprise a hot-melting resin and the heated plate 8 may comprise a textured surface so that during the hot pressing, the surface of the protective layer 4 is compressed and the agent 7 to be sublimated is evaporated and moved to the base coating 3 . However, it is conceivable that, in an alternative embodiment, the sublimation step is performed after hot pressing prior to lamination and, if possible, pressing.
    FIG. 7-12 show successive steps of an alternative embodiment of the method for manufacturing the panel 1. In this case, the substrate comprises an intermediate protective layer 9, which is attached to the base coating 3 before the agent 7 to be sublimated is applied. The substrate according to the invention in this case comprises the intermediate protective layer 9, and is supported by the base coating 3, the core 2 and the balance layer 5, respectively.
    FIG. 7 illustrates that the digital printer 6 prints the means 7 to be sublimated directly onto the intermediate protection layer 9. The intermediate protection layer 9 is a transparent layer.
    Although in this embodiment the intermediate layer 9 is defined as a protective layer, it is noted that it may be any other layer that functions as the substrate according to the invention, but which is not intended for intermediate protection.
    FIG. 8 shows that in this embodiment, after printing the agent to be sublimated 7, a protective layer 10 is applied as a further layer to the intermediate protective layer 9. The protective layer 10 can have anti-wear particles, while the intermediate protective layer 9 can be free of anti-wear particles to be. In an alternative embodiment, the intermediate protective layer 9 can also comprise anti-wear particles, for example with a size different from that containing the protective layer 10. FIG. 9-12 show the steps with regard to sublimating the agent 7 to be sublimated to the base coating 3.
    In the embodiment as illustrated in FIG. 7-12, the protective layer 10 is attached to the intermediate protective layer 9, so that the resulting panel 1 comprises the protective layer 10, see FIG. 12. This is achieved by applying a protective layer 10 made from a material that obtains adhesion properties when heated. The protective layer is made, for example, from a resin-impregnated sheet which adheres to the intermediate protective layer 9 during hot pressing. The heated plate 8 thus not only influences the sublimation process, but also attaches the protective layer 10 to the intermediate protective layer 9. In other words, the step of attaching the protective layer 10 to the intermediate protective layer 9 and the sublimation step are performed synchronously.
    In general, the layers to be laminated should not only be compatible in terms of joining together, but may also be compatible with each other in relation to wear resistance and sublimation characteristics. The intermediate protective layer 9 may, for example, comprise a melamine and polyester resin blend to obtain properties for "sublimating" the "agent" but "wear resistance", while the protective layer 10 may include a melamine for optimum wear resistance.
    According to the embodiment as shown in FIG. 16 and described above, a textured surface can be applied to the protective layer 10 before, during or after the sublimation step.
    The intermediate panel as shown in FIG. 7 and comprising an intermediate protective layer 9, base coating 3, core 2 and balance layer 5 can be stored for applying the agent 7 to be sublimated. The intermediate protection layer 9 functions as a temporary protection during storage. Therefore, the protective layer 9 can be free from anti-wear particles. The intermediate protective layer 9 and the protective layer 10 can be made of different materials, depending on desired functionalities.
    FIG. 13-16 show successive steps of an alternative embodiment of the method for manufacturing the panel 1. In this case, the means 7 to be sublimated is printed directly on the protective layer 4 before the protective layer 4 is attached to the base coating 3. The substrate according to the invention is in this case formed by the separate protective layer 4. After the printing step, the protective layer 4 with the agent 7 to be sublimated is inverted as illustrated in FIG. 14. The protective layer 4 is then laid on the base coating 3 so that the side thereof on which the means 7 to be sublimated is printed faces the base coating 3. FIG. 15 shows that the base coating 3 is supported by the core 2 and that the balance layer 5 is located below the core 2. The layers 2-5 are still separate from each other in this situation, as illustrated in FIG. 15. The stack of separate layers 2-5 is pressed under elevated temperature such that the layers 2-5 are laminated together and the agent 7 to be sublimated is simultaneously sublimated to the base coating. Therefore, one or more of the layers to be laminated may comprise a hot-melting resin, for example melamine formaldehyde, urea formaldehyde, phenol formaldehyde, or the like. During the sublimation step, the agent to be sublimated can go to the base coating 3 without going through the protective layer 4, - 7-dir-ect ~. If in an alternative embodiment the protective layer 4 is not inverted, the means 7 to be sublimated also passes through the protective layer 4.
    If the protective layer 4 comprises, for example, a paper-impregnated paper sheet or non-woven material, the agent 7 to be sublimated can be applied to the protective layer 4 before or after the impregnation process. The resin-impregnated sheet can be partially dried and partially cured to the so-called b-stage for the lamination process in which the final curing takes place, as illustrated in FIG. 16, or already before applying the means 7 to be sublimated, as illustrated in FIG. 13. If the protective layer 4 is partially dried and cured after applying the agent 7 to be sublimated, the drying / curing process must be such that the sublimation is not yet started. This can be achieved by the use of near infrared irradiation of the resin-impregnated sheet. An advantage of applying the agent 7 to be sublimated to the protective layer 4 when it is in a b-stage is that a better alignment can be achieved of the pattern of the sublimated agent 7 and a textured pressing plate in the case of desired corresponding embossing because the pattern of the agent to be sublimated is applied to the protective layer 4 after expansion of the sheet during the impregnation process. Furthermore, a layer 4 located in the b-stage has a relatively smooth surface with good characteristics for printing on it.
    In the embodiment as illustrated in FIG. 13-16, the protective layer 4 and the base coating 3 are attached to each other after printing of the means to be sublimated 7. It is also possible that the layers 2, 3, 5 are already attached to each other in the situation as shown in FIG. 15, and that in the hot-pressing step only the protective layer 4 needs to be attached to the base coating 3, while the agent 7 to be sublimated is simultaneously sublimated to the base coating 3.
    Although "" does not give "önd-Irf Tig". "13-16" is "" very good to provide anti-wear particles on the protective layer 4. For example, the anti-wear particles can be applied to the side of the substrate which is facing the base coating 3 in order to minimize the risk of damage to a pressing member contacting the protective layer 4. It is also possible to use the anti-wear particles on the opposite side of the protective layer 4 which of the core 2 is oriented to prevent the particles 7 from being impeded during sublimation.
    The protective layer 4 may comprise a resin-impregnated sheet, for example a paper sheet or non-woven material. The protective layer 4 may itself comprise a number of sheets or films. It can also be provided with a coating for improving its recording properties for receiving the sublimable agent 7. Furthermore, the protective layer 4 can be provided with a textured surface before or after the application of the sublimable agent 7. If the protective layer 4 is pressed in after applying the agent to be sublimated, it can be pressed in before, during or after the sublimation step. As described above, it is an advantage to synchronously depress the protective layer 4, to laminate the protective layer 4 to the base coating 3 and to sublimate the agent 7 to be sublimated.
    FIG. 17-20 show successive steps of yet another. alternative embodiment of the method for manufacturing the panel 1. In this case, the means 7 to be sublimated is printed directly on the intermediate protective layer 9. The substrate according to the invention in this case comprises the intermediate protective layer 9. Subsequently, the intermediate protective layer 9 with the agent 7 to be sublimated is inverted as illustrated in FIG. 18. In a next step, a stack of separate layers 5, 2, 3, 9, 10 is made, as seen from the bottom to the top: balance layer 5, core 2, base coating 3, intermediate protective layer 9 with the printed agent to be sublimated 7 and the protective layer 10. This is illustrated in FIG. 19. The stack of layers 5, 2, 3, 9, 10 is "gépér's" so vighbögdê "témperätüüf" that "they" are laminated together and the agent 7 to be sublimated is simultaneously sublimated to the base coating 3. The intermediate protective layer 9 and / or the protective layer 10 may comprise sheets impregnated with resin. In the resulting panel 1, the decorative pattern of the sublimated means 7 lies deeper in the panel than in the previous embodiment as shown in FIG. 16.
    According to the previous embodiment as described above, printing of the agent to be sublimated 7 on the intermediate protective layer 9 can be performed before or after the impregnation process if the intermediate protective layer 9 comprises a resin-impregnated sheet.
    In this embodiment, anti-wear particles can be provided on the intermediate protective layer 9 and / or the protective layer 10.
    FIG. 21 illustrates a manufacturing process in which the step of printing an agent to be sublimated 7 on an intermediate protective layer 9, the step of applying a second protective layer 11, the step of applying the protective layer 10, and the lamination step are shown.
    An intermediate panel is supplied to a conveyor belt 12, as shown on the right-hand side of FIG. 21. According to the embodiment as shown in FIG. 7, the intermediate panel comprises the intermediate protective layer 9, the base coating 3, the core 2 and the balance layer 5, as viewed from the top to the bottom of the intermediate panel. The means 7 to be sublimated is printed on the intermediate protective layer 9 by means of the digital printer 6. Subsequently, the second intermediate protective layer 11 is applied to the top of the printed intermediate protective layer 9 by applying a protective coating. In a next step, a powder mixture of corundum and ionomer on the top of the second intermediate protective layer 11 is spread by means of a powder device 13, so that the protective layer 10 is created. The intermediate panel with the added layers is transported to a vehicle 4 during transport. During hot pressing, the agent 7 to be sublimated is sublimated to the base coating 3, the second intermediate protective layer 11 is attached to the intermediate protective layer 9 and the protective layer 10, and the ionomer powder of the protective layer 10 is melted so that the corundum particles are embedded in the ionomer layer.
    It will be clear from the foregoing that the invention provides an efficient method for manufacturing a panel.
    The invention is not limited to the embodiments described above as shown in the drawings, which can be varied in various ways without departing from the scope of the invention. For example, separate layers that can be attached to each other by hot pressing can be pressed by a continuous pressing process, for example by calendering. Accordingly, the sublimation step can be performed through a continuous process. The press plate can be provided with a textured surface or there can be a textured release sheet between the press plate and the stack to be laminated.
    权利要求:
    Claims (14)
    [1]
    CONCLUSIONS
    A method for manufacturing a panel (1) comprising the steps of: supplying a substrate (4, 9), applying a means to be sublimated (7) on at least one side of the substrate (4, 9), applying a recording layer (3) for recording the means to be sublimated (7) when sublimating, securing the substrate (4, 9) and the recording layer (3) together, sublimating the means to be sublimated (7) to the recording layer (3) to form a panel (1) provided with the substrate (4, 9) and the recording layer (3) with the means to be sublimated (7), wherein the means to be sublimated (7) as a separate substance is applied directly to the substrate (4, 9).
    [2]
    A method according to claim 1, wherein the means (7) to be sublimated is printed by a digital printer (6) on the "substrate" (47 9).
    [3]
    A method according to claim 1 or 2, wherein the substrate (4, 9) and the recording layer (3) are attached to each other before the means to be sublimated (7) is applied, so that an integral unit is formed before the means to be sublimated (7) is applied.
    [4]
    A method according to any one of the preceding claims, wherein the substrate comprises a protective layer (4) with anti-wear particles.
    [5]
    A method according to claim 3, wherein a further layer (10) is applied to the substrate (9) after applying the agent to be sublimated (7), wherein the substrate (9) and the further layer (10) with resin impregnated sheets may comprise which resin of the substrate (9) and the further layer (10) are compatible with each other.
    [6]
    A method according to claim 5, wherein the substrate comprises an intermediate protective layer (9) and the further layer (10) comprises a protective layer with anti-wear particles, wherein preferably the intermediate protective layer (9) is a transparent layer.
    [7]
    A method according to claim 5 or 6, wherein the substrate (9) and the further layer (10) are attached to each other synchronously with the sublimation step.
    [8]
    A method according to claim 7, wherein the further layer (10) comprises a resin-impregnated overlay sheet that is hot-pressed to the substrate (9) under which conditions the sublimation step takes place. .
    [9]
    A method according to claim 1 or 2, wherein the substrate (4, 9) and the recording layer (3) are attached to each other after applying the agent (7) to be sublimated.
    [10]
    A method according to claim 9, wherein the steps with respect to the securing of the substrate (4, 9) and the recording layer (3) and with respect to the sublimation are performed synchronously.
    [11]
    A method according to claim 10, wherein the steps with respect to fastening and with respect to sublimation in a lamination process are carried out under elevated temperature and pressure. A method according to "claim 11, wherein one or more layers (2, 5, 10) are laminated to the substrate (9) and the recording layer (3).
    [13]
    A method according to any one of claims 9-12, wherein the side of the substrate (4, 9) on which the means to be sublimated is applied faces the recording layer (3) or faces away from the recording layer (3).
    [14]
    A method according to any one of the preceding claims, wherein the recording layer (3) is attached to a core (2) that is substantially impervious to the agent (7) to be sublimated.
    [15]
    A method for manufacturing a panel (1), comprising the steps of: supplying a substrate (4) provided with a recording layer (3) for recording a sublimable agent (7), applying a sublimable means (7) on at least one side of the substrate (4), sublimating the means to be sublimated (7) in the recording layer (3) to form a panel (1), wherein the sublimable means (7) when a separate substance is applied directly to the substrate (4).
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    同族专利:
    公开号 | 公开日
    EP2708374A1|2014-03-19|
    WO2014041080A1|2014-03-20|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    EP0914972A1|1997-11-04|1999-05-12|Cimer Création Industrielle Meuble du Royans|Process for making a decorative panel imitating tiles and panel obtained by the said process|
    US6686315B1|2000-03-08|2004-02-03|Digital Dimensional Stone, Llc|Simulated surface building materials and process for making the same|
    US20040026017A1|2002-08-07|2004-02-12|Taylor Dene H.|Method and system for producing a wood substrate having an image on at least one surface and the resulting wood product|
    WO2005106153A1|2004-04-27|2005-11-10|Trio Industries Group Inc.|Protective panels and doors|
    US20110056617A1|2009-09-08|2011-03-10|Jonathan Haile Cagle|Method of making special event custom signs in color with text and graphics|
    EP2930031B9|2014-04-09|2018-04-25|Akzenta Paneele + Profile GmbH|WPC decorative panel with low porosity profile edge and method for producing the same|
    法律状态:
    2020-08-21| MM| Lapsed because of non-payment of the annual fee|Effective date: 20191130 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP121845119|2012-09-14|
    EP12184511.9A|EP2708374A1|2012-09-14|2012-09-14|A method of manufacturing a panel|
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