CN102834275B - 一种制造地板的方法 - Google Patents

一种制造地板的方法 Download PDF

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CN102834275B
CN102834275B CN201180013327.7A CN201180013327A CN102834275B CN 102834275 B CN102834275 B CN 102834275B CN 201180013327 A CN201180013327 A CN 201180013327A CN 102834275 B CN102834275 B CN 102834275B
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布鲁诺·韦尔默朗
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Flooring Industries Ltd SARL
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/20Applying plastic materials and superficially modelling the surface of these materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065After-treatment
    • B05D3/067Curing or cross-linking the coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50Multilayers
    • B05D7/52Two layers
    • B05D7/54No clear coat specified
    • B05D7/542No clear coat specified the two layers being cured or baked together
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41FPRINTING MACHINES OR PRESSES
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/22Removing surface-material, e.g. by engraving, by etching
    • B44C1/227Removing surface-material, e.g. by engraving, by etching by etching
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
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    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F9/00Designs imitating natural patterns
    • B44F9/02Designs imitating natural patterns wood grain effects

Abstract

本发明提供了一种制造地板的方法,包括以下步骤:提供一板(2);以预定图案样式将可固化物质或表面去除物质印刷在板(2)上,以便相应地以所述图案样式在板(2)上产生隆凸或者以所述图案样式去除板(2)的一部分表面;固化可固化物质或去除表面去除物质与板(2)的任何反应产物。

Description

一种制造地板的方法
本发明涉及一种制造地板的方法。
在地板业领域中,如同其它一些行业一样,存在一种大规模定制的趋势。这意味着存在一种对适合于特定客户的产品的需求。因此,在生产过程中需要高度的灵活性。
本发明的目的是提供一种制造地板的方法,其给在地板上做出浮雕样式提供很大的灵活性。
上述目的是通过根据本发明的制造地板的方法来实现的,该方法包括以下步骤:提供一板;以一预定图案样式将一可固化物质或表面去除物质印刷到板上,以便对应地以这个图案样式在板上产生一隆凸或者以这个图案样式去除板的一部分表面;固化可固化物质或者去除表面去除物质与板的任何反应产物,从而形成地板。
归因于根据本发明的方法,不必要使用比较昂贵的压纹压板或压辊来在板上被以高压按压以产生地板的压纹表面。此外,该方法提供了使地板的浮雕样式产生高度变化的机会。相似程度的样式变化如果使用不同的压纹压板或压辊来实现的话,将会更加昂贵。
在一优选实施例中,印刷步骤是数控的和/或非接触印刷和/或非接触。归因于该数控步骤,可以实现向制造具有选择性的浮雕样式的地板的快速转换。这在浮雕样式中引入很大的灵活性,并且避免了例如在使用现有技术压纹辊或压纹板时的重复压纹的必要性。这意味着,标准化基础产品可被有效地进一步处理以形成相应于个别客户需求的独特产品。更具体而言,可以通过一数控印刷喷嘴将所述物质印刷在板上。
尽管如此,还可以想到通过滚筒印刷或选择现有技术印刷方法将可固化物质或表面去除物质印刷在板上。为了改变待印刷的图案样式,可以使用具有不同图案样式的多个印刷滚筒。例如,它们可以被转筒式安装,以便能够迅速地转变至待印刷在板上的各种样式。
板可以包括HDF、WPC(木塑复合材料)、聚合物复合材料(工程聚合物)、PVC、LVT(奢华乙烯基板材)等的基材。该板可以具备装饰性基础图案,所述装饰性基础图案直接印刷在基材上或通过已知的层压方法层压在其上。此外,所提供的板可以已经包括一压纹,但也可以具有一平面,可固化物质或表面去除物质印刷在该平面上。可以通过固化方法固化可固化物质,例如通过紫外辐射或紫外激光。可选择的固化方法可以包括电子束加热或在高温下正常加热;例如,可以将包括可固化物质的整个板放置在受热环境中以固化该物质。
可固化物质可以包括耐磨颗粒,以便提供地板的隆起部分在实际使用中的的良好磨损性能。
在一具体实施例中,预定图案样式基本对应于板上存在的装饰性基础图案。这意味着,地板将具备互相对准的压纹。在实践中,图案样式可以是木纹图案,其中木纹是凹陷部分,而周围部分是隆起部分。可以通过在预期的凹陷部分上印刷表面去除物质或者在所预期的凹陷部分之外的部分印刷可固化物质来制成凹陷部分。
可以通过首先以所述预定图案样式将液体印刷在板上,并随后向该液体提供一中间物质来将可固化物质或表面去除物质印刷在板上,其中,中间物质或液体连同中间物质一起形成可固化物质或表面去除物质。在实践中,中间物质可以包括一种粉末。该粉末可以施加在液体上并且粘附于该液体,但是大量粉末例如通过一抽吸装置除去。优选地,中间物质包含耐磨颗粒,因为这提供将无耐磨颗粒的液体印刷在板上的机会,以避免磨损印刷头,然而,包括耐磨颗粒的粉末可以较不精确地施加至印刷液体。
在实践中,可固化物质的最大厚度介于50μm和250μm之间,但可以想像得到更薄或更厚的层。优选地,最大厚度介于5μm和1000μm之间。
可固化物质可以包含清漆,其例如是有光泽的或亚光的。
还可能的是,板是柔性片材,在其上印刷可固化物质或表面去除物质之后,该柔性片材被层压至一基材,从而形成地板。例如,该片材是一纸质片材,其已具备树脂或者还必须具备树脂。
在一选择性的实施例中,方法包括以下步骤:提供一板;以一预定图案样式将一可固化物质或表面去除物质施加至所述板上,以对应地以所述图案样式在板上产生一隆凸或者以所述图案样式去除所述板的一部分表面,其中,首先通过将一层物质放在板上,并随后通过一数控冲击元件产生预定图案样式来将物质施加在板上,该数控冲击元件压入所述物质中,并可在平行于板的一平面中移动以形成所述图案样式;固化可固化物质或者去除该表面去除物质与板的任何反应产物,从而形成地板。该方法的优点在于,不必使用昂贵的现有技术中的压纹压板来产生压纹地板,但可以实现向所想要的浮雕样式的迅速改变。
在实践中,冲击元件的尺寸将小于板的尺寸。该冲击元件可以比得上传统的点阵印刷机,其中数控针经由墨带冲击纸张。这种方法适用于部分固化的顶层,例如聚氨酯(PU)热涂顶层。对冲击元件的控制可以基于图像识别,例如,识别接近的板的图案的相机。
下文将参照附图更加详细地解释本发明,这些附图是本发明的实施例的示意图。
图1是实施根据本发明的方法的一实施例的装置的示意性侧视图。
图2是一替代性实施例的与图1类似的视图。
图3是另一替代性实施例的与图1类似的视图。
图1图示了根据本发明的方法的一实施例的主要步骤。装置1所执行的制造过程在图1中从右至左进行。在此情况下,一板2首先被输送至一数字印刷站3。在数字印刷站3处,以一预定图案样式将一液体印刷在板2的上表面上。该液体可以是油墨或清漆,其为透明的或彩色的或任何其它液体材料。
然后,将已印刷的板2输送至粉末单元4,其中,将一中间物质或一粉末5涂撒在板2上。粉末5将粘附至液体。液体和粉末5形成可固化的物质。粉末5的一部分可能落在印刷图案旁边或者落在已干燥的印刷图案部分上。粉末5的该部分将由抽吸装置6从板2去除,然而,可以想到其它替代性的粉末去除装置。
在后续步骤中,板2上形成的物质在加热站7处被固化。在储存站9处储存所得地板2a之前,可以在冷却站8处冷却板2。在加热站7中,粉末可以熔融在一起成为隆起在板2的初始上表面之上的单个块状物。可以想到的是,液体和粉末一起形成可固化物质,或者粉末自身形成固化后粘附于板2上的可固化物质。
还可以想到的是,粉末形成可固化物质,然而,液体图案仅充当用于在所想要的图案样式中携带粉末的临时载体。在此情况下,在加热步骤中液体可部分或完全地消失,例如通过蒸发。
粉末5可以是膨胀粉末,以使得固化后物质的体积比单独的液体和粉末5的体积之和变得更大(及隆凸更高)。在实践中,固化后物质的最大厚度介于50μm和250μm之间,但更高或更低的厚度是可以想到的。在实践中,5-1000μm的厚度是优选的。
此外,粉末5还可以包含耐磨颗粒,例如金刚砂颗粒。有利的是,在如图1所示的实施例中,由数字印刷站的印刷头来单独提供耐磨颗粒,从而基于耐磨颗粒的存在避免印刷头的磨损。
归因于液体和粉末5的混合物的固化或粉末5单独的固化,在板2上于印刷有液体图案的位置处产生固体隆起区域。该图案可代表实木图案等等。例如,加热站7可包括紫外激光器,但是其它替代性的固化装置是可以想到的。
图1的装置可包括相机(未图示),该相机用于在板2抵达数字印刷站3之前识别板2上印刷的基础图案。在数字印刷站3处印刷在板2上的图案可对应于基础图案,以使得板2获得互相对准的压纹。
可以想到若干类型、形状和尺寸的粉末5。例如:金属树脂粉末,其在熔融之后产生金属效果;有光泽的树脂粉末,其中粉末添加了有光泽的颗粒;抗静电粉末,其避免静电电荷堆积;产生珠光效果、亚光效果、或芳香效果的粉末。
在一替代性实施例中,以预定图案样式在印刷站10处将可固化物质直接印刷在板2上。这反映在图2中。在此情况下,相当大量的物质必须经由印刷站10来印刷。所描述的与图1所示实施例有关的其它特征也适用于图2所示的实施例。
在根据本发明的方法的又一替代性实施例中,在一物质涂撒装置11处将一层物质涂撒在板2上,然后通过数控冲击元件12产生预定浮雕样式,参见图3。在此情况下,可将物质均匀地涂撒在板2上。数控冲击元件12被可重复地压入可固化物质中,且可在平行于板2延伸的平面中移动以形成浮雕样式。所描述的与图1所示实施例有关的其它特征也适用于图3所示的实施例。
还可以想到的是,例如由抽吸装置从板上局部地去除物质,而非由冲击元件12局部地移置物质。
在另一可选择的方法中,可以(直接地或间接地通过如上所述的印刷液体中的粉末)将表面去除物质施加至板上,以使得在预期图案处去除板2的局部表面。可以按如图1和图2所示的方式将物质施加到板上。物质的选择应使其与板2的表面反应,以便去除该表面的一部分。与上述实施例相反,板2的浮雕样式通过从板2上去除材料而非添加材料来形成。例如,在对板上的基材进行加热和/或冷却之后,可以通过压缩空气去除任何反应产物。也可能,在该实施例中,加热和冷却都不是必需的。在以此种方式做出压纹之后,可以用包含耐磨颗粒的最终装饰层覆盖该板。
或者,表面去除物质的选择应使得在被活化之后与板2的表面反应。例如,可以通过热源、紫外辐射、激光束等来活化该物质。当以预定图案样式将表面去除物质印刷在板2上时,活化装置不需要十分准确地集中在板表面的特定区域,因为仅有其中存在物质的那些区域将被活化。在物质的活化和与板表面的反应之后,可以去除任何反应产物。
具有相同的装饰性基础图案的板可以具备不同的浮雕样式,例如,一种为精确叠合压纹型,另一种为全面涂刷型。这增大了地板外观的变化。
施加了可固化物质或表面去除物质的板2可以由HDF、WPC、聚合物复合材料或工程聚合物、LVT、PVC等制成。应注意,根据本发明的方法还可以应用在柔性片材上,该柔性片材将在后期阶段层压至基材,以形成地板。
本发明并不限于附图中所示的实施例,而是可以在本发明的范围内以若干方式变化。例如,有可能将该方法应用在除板或片材之外的替代性基材上,例如,应用在地板的包装材料上。此外,数字印刷站可以由替代性印刷装置替换,例如,现有技术的滚筒印刷工艺中已知的传统印刷滚筒。

Claims (14)

1.一种制造地板的方法,包括以下步骤:
提供一板(2);
以一预定图案样式将一可固化物质印刷在板(2)上,以便相应地以所述图案样式在板(2)上产生一隆凸,其中,通过首先按预定图案样式将一液体印刷在板上并随后将一粉末(5)涂撒在板上来将可固化物质印刷在板(2)上,粉末或者液体连同粉末一起形成可固化物质,未粘附于液体的部分粉末被除去;
固化所述可固化物质,形成地板。
2.根据权利要求1所述的方法,其中,印刷步骤是数控的和/或通过非接触印刷或滚筒印刷完成。
3.根据权利要求1所述的方法,其中,可固化物质包括耐磨颗粒。
4.根据权利要求1所述的方法,其中,所述预定图案样式大致对应于一存在于板(2)上的装饰性基础图案。
5.根据权利要求1所述的方法,其中,粉末(5)包含耐磨颗粒。
6.根据权利要求1所述的方法,其中,粉末(5)是膨胀粉末,以使固化后物质的体积比单独的液体和粉末(5)的体积之和变得更大。
7.根据权利要求1所述的方法,其中,由粉末(5)形成可固化物质,液体图案仅充当用于在所想要的图案样式中携带粉末(5)的临时载体。
8.根据权利要求1所述的方法,其中,粉末(5)选自:金属树脂粉末,其在熔融之后产生金属效果;有光泽的树脂粉末,其中粉末添加了有光泽的颗粒;抗静电粉末,其避免静电电荷堆积;产生珠光效果、亚光效果、或芳香效果的粉末。
9.根据权利要求1所述的方法,其中,可固化物质的最大厚度介于20μm和250μm之间,或介于5μm和1000μm之间。
10.根据权利要求1所述的方法,其中,可固化物质通过加热、紫外辐射、紫外激光或电子束加热来固化。
11.根据权利要求1所述的方法,其中,可固化物质包括清漆。
12.根据权利要求1所述的方法,其中,板(2)是柔性片材,在柔性片材上印刷可固化物质之后,该柔性片材被层压至一基材以形成地板,或者,板(2)包括一HDF、WPC、聚合物复合材料、PVC或LVT的基材。
13.根据权利要求1所述的方法,其中,板具有装饰性基础图案,所述装饰性基础图案直接印刷或层压在其上。
14.根据前述权利要求之一所述的方法,其中,液体为油墨或清漆,其为透明的或彩色的。
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