DE102010045266A1 - Method for manufacturing component for lining of e.g. floor surface of building, involves applying upper decoration part of ink above non-woven fabric layer before or after applying non-woven fabric layer on base body - Google Patents

Abstract

The method involves applying a non-woven fabric layer (3) on a planar base body (2) i.e. timber material plate. An upper decoration part (6) of ink is applied above the non-woven fabric layer before or after applying the non-woven fabric layer on the base body by a digital inkjet printing process. The upper decoration part is cured by UV light. The non-woven fabric layer is provided with protecting layers (5a, 5b) before and after printing. The protecting layers are formed from a resin and paint. One protecting layer is provided with wear resistance increasing particles. An independent claim is also included for a component for lining a floor surface, a wall surface or a ceiling surface.

Description

The invention relates to a method for producing a component for covering floor, wall or ceiling surfaces according to the features in the preamble of claim 1 and a component produced by this method for covering such surfaces according to the features of claim 13.

Cladding components serve the visual design as well as enhancement and refinement of visible area proportions. Within buildings, for example, they are suitable for covering walls, ceilings or floors. Their production is usually in the form of panels or plates. On the other hand, elements that set accents or border the edges are usually executed as ornaments or in the form of strips. The visible in the installed state surfaces have either their natural material character or otherwise imparted optics, such as a specially applied decor.

In the prior art, these Oberflächendekore be printed. Their production is usually done by direct printing. The respective decor is applied via a pressure roller either directly on a plate or only on a paper layer, which is then connected to a plate-shaped base body. In this way, in particular, the production of laminate takes place.

By the DE 10 2008 033 274 A1 For example, a method for printing on printing paper from a roll with at least one decorative image having decor for use in sheet-like components, in particular for floor, wall, ceiling or furniture applications, the prior art. In this case, a predetermined print image is provided on a paper section of the printing paper with a predetermined length, which is printed by a digital printing device by a digital printing device. Subsequent paper sections may have a different, further decorative image than the decorative image of the preceding paper section. As a result, different decorative images can be printed on a roll of printing paper with increased variability.

Digital printing in connection with floor elements or wall or ceiling panels is also used in the DE 10 2007 013 132 A1 described. The individual sheet-like printed components are, in particular, wood-based panels such as MDF, HDF or DKS boards or so-called HPL (High Pressure Laminate) boards. It is proposed to apply a printed paper layer to the upper side of the base body and to firmly connect it to the base body. On the color layer of the paper layer, a protective layer is then applied, which serves to protect the ink layer from UV radiation and in particular mechanical damage. The protective layer is transparent.

The usual procedure for the production of flat components is that the paper layers are first printed by means of a printing process with a decor. This can be a rotogravure printing method in which a printing body comes into contact with the paper layer. The thus printed paper layer is provided with a protective layer, that is, it is impregnated.

The usual web widths in gravure printing processes are between 2.0 m and 5.5 m. For further processing, the decorative paper webs are often separated after the pressure to a narrower extent. The usual web widths are then at 1.25 m and 2.1 m. These two widths are common formats which are used in the impregnation with aminoplastic resins.

The paper used is usually soaked. It is also possible to apply the resin used for the impregnation asymmetrically on the printed paper web. After impregnation, the resin is first dried until its partial condensation. The final curing takes place only after the decor paper is pressed with the base body.

Such a pretreated paper web is brittle after its impregnation. Their stiffness increases greatly compared to a non-impregnated paper web. Disadvantage of this manufacturing order is that the paper undergoes growth through printing and impregnation. In order to obtain a decore-synchronous structure during compression by means of a press plate, the value of the growth must be known exactly. This is the only way to achieve correct results.

Here, it is assumed that the press plate is not absolutely flat, but has a structure or differences in roughness (gloss differences), which must be matched exactly to the decor. An offset between the decor and the surface profiling leads to a perceived as unrealistic optics. As a result, the otherwise desired realistic surface impression, for example in the form of a wood structure, at least partially lost.

In particular, in the production of laminate in addition to the respective appearance increased demands on the surface resistance posed. In the laminate sector, this is above all due to the wide variety of possible uses, each of which entails different loads.

The resistance of a laminate, depending on the structure, is grouped into standardized stress classes, from which the corresponding utilization classes result. The stress classes of laminate flooring are used in the EN 13329 regulated. Following the purpose of use, the appropriate product can be selected in a targeted manner. The classes for the living area range from 21 to 23. In particular, for commercial use classes recommend starting with 31.

The construction of clad components known in the prior art still offers room for improvement, especially for use in heavily loaded areas. In particular, the subject of the mechanical wear component surface is in focus.

The invention is therefore an object of the invention to optimize a method for producing a component for covering floor, wall or ceiling surfaces and such a component manufacturing technology, that in addition to a good print image of the decor improved resistance of the component surface is achieved.

The solution to this problem consists according to the invention in a method with the features of claim 1.

Thereafter, a method for producing a component for covering a floor, wall or ceiling surface is provided in which a nonwoven layer is applied to a flat body. Before or after the application of the nonwoven layer to the base body, an upper decor of ink is applied above the nonwoven layer. The upper decor is produced by means of a digital ink jet printing process.

The nonwoven fabric is a textile fabric of individual fibers. Unlike paper, the individual fibers used are longer. In principle, wet laid nonwovens of short cellulosic fibers similar in length to paper can also be used. Unlike the paper, however, the nonwoven layer has no hydrogen bonds. The nonwoven layer used may be loosely connected fibers which are not yet joined together. The strength of the nonwoven layer is based on the fiber's own adhesion. The strength of the nonwoven layer can be influenced by work-up. The workup of the nonwoven layer leads to their solidification.

The nonwoven layer can be formed, for example, from a glass fleece or polyester. In principle, the nonwoven layer can also be formed from a combination of glass and polyester. The arrangement of the nonwoven layer is not limited to a single layer, but may also be composed of several layers. The basis weight of the nonwoven layer is, for example, from 25 to 190 g / m ² . Advantageously, the basis weight of the nonwoven layer is from 90 to 160 g / m ² .

The arrangement of the nonwoven layer provides the component with a high resistance to mechanical wear, which is higher than that of paper. The high resistance of a component provided with a nonwoven layer has a very good impact resistance against impacting bodies as well as a high resistance to scratching. In particular, the use of a glass fleece layer leads to a very good fire behavior of the component. In addition to the surface against abrasion-enhancing properties of the nonwoven layer eliminates the arrangement of the usual in the art paper, the elimination saves appropriate material costs.

The nonwoven layer may have other characteristics in addition to their strength properties. Depending on the configuration of the nonwoven layer, it may have electrically conductive fibers, so that a possible shielding against electric fields is achieved. Furthermore, the nonwoven layer can also have antistatic properties.

Another advantage lies in the high cover quality of the nonwoven layer, so that the superficial properties of the base body do not shine through. In addition, the nonwoven layer also reliably covers a possible surface structure of the main body, so that a thermoforming of the main body is prevented. Thus, the arrangement of the nonwoven layer prevents possible negative effects on the surface design of the component.

Further advantageous measures of the method according to the invention are content of the dependent claims 2 to 12.

For printing, a UV-curable ink is used, which is cured immediately after the printing process by the irradiation with UV light. Conventional aqueous inks or solvent-based inks run on the nonwoven layer, so that no sharp print image is achieved. These inks must also be dried by means of heat, usually by means of infrared rays. The required heat input can negatively influence the layer structure, for example by thermal expansion.

The printing by means of curable by UV light ink can basically be done partially or all over. It is also possible to make several print jobs in succession.

The nonwoven layer is provided with a protective layer prior to printing. The protective layer can be placed on the nonwoven layer. Advantageously, the nonwoven layer is impregnated with the protective layer, so that the protective layer at least partially penetrates into the nonwoven layer. The protective layer is thus an impregnate. In combination with the UV light curing of the decoration, only a small amount of heat is introduced into the nonwoven layer impregnated in this way, so that the impregnate contained in the nonwoven layer by the impregnation is not impaired. Overall, this results in lower elongations, whereby a porosynchronous production between the printed decor and a profiled press plate is simplified. Nonwoven webs that are printed in roll unwinding stations undergo longitudinal stretching while constricting their width. By avoiding printing inks or aqueous-based inks, which can lead to growth of the nonwoven layer, the growth-triggering parameters are eliminated from the outset with the method according to the invention.

Another advantage is that this procedure simplifies handling. Today's state of the art is to let the decor in a printing on a paper layer to print. Subsequently, the printed paper layer is impregnated and finally pressed with a manufacturer of, for example, laminate flooring with the main body. In the invention, however, a printed or unprinted base fleece procured and impregnated in advance, only then apply the desired decor with a digital printer, which can be pressed without prolonged drying times directly in a press together with the body in particular to a laminate floor. The application rate of the ink used may be between 1 g / m ² to 10 g / m ² , preferably between 3 g / m ² and 6 g / m ² .

The inventive method is thus suitable for the production of sheet-like components such as doors, wall cladding panels, but especially for furniture parts, such as kitchen furniture fronts.

Advantageously, the impregnate, that is to say the protective layer, is formed from a resin. This is preferably an aminoplast.

Another advantage is considered that the digital printer does not require a complex winding and unwinding station for the fleece. The resin-impregnated non-woven layer has a certain rigidity and can not be easily bent. Therefore, it is guided in individual sheets through the digital printer. The transport of the individual non-woven sheets can be done via suction.

A preimpregnation of the nonwoven layer forms an excellent substrate for the particular UV curable ink, since the ink can not penetrate deep into the nonwoven layer. As a result, it is to some extent on the surface of the impregnated nonwoven layer. This leads to an extremely sharp print image. Conventional ink, in particular solvent-containing inks, would run on an impregnated nonwoven layer or lead to reactions of the impregnating resin in the drying of the ink. However, the use of UV curable ink does not cause any reaction with the impregnating resin. It also does not bleed the ink, resulting in the desired, crisp print image.

In a variant of the method according to the invention, the nonwoven layer is provided with a protective layer only after printing. In this case also the initial impregnation of the nonwoven layer with the subsequent arrangement of an additional protective layer after printing is possible. By applying a protective layer after printing, the generated decoration is sealed.

Advantageously, the protective layer is formed from a resin. The resin used is preferably an aminoplast. The term aminoplast is used both for the precursor to be cured and the through-hardened end product.

In particular, for a subsequent after printing applying a protective layer, the invention provides that this protective layer is formed from a lacquer. In addition to the decor at least partially covering paints and the decor over the entire area or only partially toning paints can be used. Basically, mostly transparent paints are used here. In addition to their function as a protective layer, the decors are improved in their optical effect especially when applying tinted or transparent paints.

If necessary, at least one of the protective layers can be provided with solids. In this case, preferably provided for the order on the printed nonwoven layer protective layer is at least partially provided with individual particles. These can be incorporated, for example, in the already applied paint or the applied resin. In particular, the abrasion and To increase the scratch resistance of the protective layer, it is provided with the abrasion-resistant particles. The material, for example corundum, silicon or ceramic, in particular porcelain, is in this case glued to the protective layer or already bonded to it in the production of the protective layer. The particle size of the particles preferably ranges from 2 to 100 mμ (mü). The present in appropriate grain material is mixed, for example, in the protective layer to be applied and applied together with this.

In principle, however, the individual particles can also subsequently be sprinkled onto the not yet cured protective layer and incorporated. In particular, in an impregnation, the individual particles may be interspersed in the not yet cured resin. The particles can be chosen so that the perceptible surface characteristics of the component is selectively changed. As a result, the particles create / change the desired visual impression. The particles are used as elements of design giving character, for example in the form of mica. In this way, a desired gloss value of the surface can be set generally or only in certain areas. In addition to a modified appearance of the so coated component in particular its useful areas and applications are extended. Preferred applications are, for example, in areas with increased requirements for slip resistance, as prevail, for example, laid in entrance areas flooring. In addition, the rough structure of the protective layer also increases the resistance of the component to mechanical stress.

Depending on the requirement, the protective layer provided for the application on the printed nonwoven layer is provided with a rough structure. This can be incorporated, for example, in the already applied paint or the applied resin. Even if the rough structure can be transferred to the protective layer, for example, by means of a shaping tool, it is produced in an advantageous manner by the application or introduction of a further material into or onto the protective layer. The material, for example corundum, silicon or ceramic, in particular porcelain, is in this case glued to the protective layer or already bonded to it in the production of the protective layer.

Depending on the requirement and the desired end result, the invention provides that the nonwoven layer is first printed with a lower decor before printing with the upper decor. The lower decor is produced by means of a printing process in which a pressure body comes into contact with the nonwoven layer. In contrast to the contactless ink-jet printing process, in which tiny ink droplets are accelerated and thus applied to the desired surface area, the formation of the lower decoration takes place in direct contact with a color carrier. In this respect, it is a conventional printing method, wherein the ink carrier is formed from a pressure body. This is advantageously a rotary printing process. The decor is applied by rotogravure on the nonwoven layer. The pressure body is preferably a pressure roller. Unless the rotary printing process is used, a flat pressure body for applying the lower decoration can be used.

With these conventional printing methods primarily a high processing speed should be achieved. The so pre-printed nonwoven layer is then printed in the inkjet printing process with the top decor. The overlapping of the two decors produces different effects. The second, upper decor complements and modifies the lower decor. Both decors can be applied both over the entire surface as well as part of the area. In principle, the upper decor may not be formed over the entire surface, whereby it does not replace the lower decor, but primarily serves to complement it.

It is further provided that above the nonwoven layer, an uppermost layer is applied as an overlay. Thus, the overlay seals the component towards its upper useful side. The overlay serves all underlying layers including the decor as the outermost protective layer. In this case, the overlay can also have abrasion resistance-increasing particles such as, for example, corundum, silicon or ceramic, in particular porcelain. Preferably, the overlay of resin, in particular melamine resin is formed. Overall, the overlay serves to protect against mechanical stress, for example by abrasion.

In particular, a laminate floor is produced by the method according to the invention. In this case, a support plate made of a wood material is preferably used as the base body, which is profiled edge after compression with the nonwoven layer to form a connection geometry. In particular, the properties of the nonwoven layer which prevent penetration of the main body are also made possible by the use of rough and topographically more demanding surfaces of the carrier plate, as prevail, for example, in chipboard or OSB boards. A preferred field of application for this is, for example, in the production of components for furniture.

The invention provides that a counter-pull is applied to an underside of the base body facing away from the nonwoven layer. The counter-pull is in this case applied to the underside of the main body, for example in the form of a paper or a plastic layer. The counter-pull serves to absorb bending forces, which arise both through stress and through the layers applied to the base on the upper side. Advantageously, the protective layer and the decor and the nonwoven layer and the counter-pull are connected in a common step with the body. This results in an efficient and economical production. In this joint step, the individual layers and the decor are pressed together with the base body and glued together.

It is further provided that the individual layers are pressed together with the decor and the counter-pull as well as the base body, wherein one of the nonwoven layer facing top of the main body is provided with a structure. For this purpose, the press pressure is adjusted so that a structure incorporated in a press plate is transferred through the individual layers, in particular through the nonwoven layer, into the upper side of the main body. By means of this surface structure, an extremely realistic optical effect of the visible surface of the component can be produced. Advantageously, an MDF board is used for this purpose, into which the structure of the press plate is transferred through individual layers, in particular through the nonwoven layer.

The solution of the objective part of the task according to the invention in a component having the features of claim 13.

Advantageous embodiments are the subject of the dependent claims 14 to 17.

The finished sheet product is a component for covering floor, wall or ceiling surfaces with a flat base body in the form of a profiled carrier plate at the edge. On the body, a nonwoven layer is applied. Before or after applying the nonwoven layer to the base, an upper decor of ink is applied over the nonwoven layer by a digital ink jet printing process. The nonwoven layer can be provided with a suitable protective layer both before and after printing. In the arrangement of the protective layer before printing the nonwoven layer, the protective layer is advantageously formed by a resin through which the nonwoven layer is impregnated. The arrangement of the protective layer after printing can be done both via resin and over paint.

Advantageously, the decor is formed from UV-curable ink. In particular, the ultraviolet-curable properties of this ink cause a sharp image of the decoration to be created upon application of this ink and instantaneous UV curing.

In order to obtain the most natural possible surface characteristic of the component, the invention provides that an upper side of the base body facing the nonwoven layer has a structure. This structure can be introduced, for example, before applying the nonwoven layer in the body. Advantageously, this structure is produced in a common operation, wherein the structure is introduced through a correspondingly formed press plate through the nonwoven layer into the top of the body.

Already before the printing of the nonwoven layer with the upper decor, a lower decoration may first be applied above the nonwoven layer. The lower decor is produced by means of a printing process in which a pressure body comes into contact with the nonwoven layer.

In particular, in the laminate area, a protective layer is applied to the nonwoven layer before pressing to protect the decor or generally the nonwoven layer from damage. The nonwoven layer thus provided with the protective layer is cut before being pressed.

It is also possible within the scope of the invention to use other carrier plates as the base body as those made of wood-based materials, wherein it may be necessary to glue the decorative layer to the base body or to glue it. Depending on the choice of the base body, a counter-pull to stabilize the layer structure on the base body may be necessary. The marginal profiling of the main body is in particular a profiling of a glue-free so-called click system, in which adjacent basic body can be positively connected to each other.

In order to increase the abrasion resistance, at least one of the protective layers, preferably the uppermost layer and thus the component that delimits its useful surface, may have individual solids in the form of particles. As a result, the resistance of the uppermost layer is increased as a mechanically loaded wear layer. Thus, for example, corundum, silicon or ceramic, in particular porcelain, as well as a combination of the above may already be mixed in the resin and / or lacquer before its application. The particles may also be interspersed in the not yet hardened resin and / or lacquer, for example in the impregnation, and harden together with this. It is conceivable also a previous order of the particles, which are then at least partially superimposed with resin and / or paint.

According to the requirements, the component may have an overlay on its upper wear layer. The overlay forms the uppermost protective layer, which protects against abrasion, in particular under mechanical stress. The overlay can have its abrasion resistance-increasing particles.

The invention will be explained in more detail with reference to embodiments schematically illustrated in the drawings. Show it:

1 an inventive component in a sectional view and

2 the component of the invention 1 in a variant.

The 1 shows a planar component 1a , of which only a portion of the surface is shown in cross-section. Carrying element of the sheet-like component 1a is a basic body 2 , The main body 2 even can be constructed in one or more layers and consists in particular of wood and / or plastics. In particular, it may be in the main body 2 be wood-based panels, such as MDF, HDF or DKS boards, or so-called HPL (High Pressure Laminate) plates act.

On the main body 2 is a printed fleece layer 3 applied. The fleece layer 3 is printed several times. In this embodiment, two printing layers are applied one above the other. A lower print layer represents a lower decor 4 This lower decor 4 is by means of a rotogravure method on the nonwoven layer 3 applied. The lower decor 4 is not used for equalization in the sense of a primer, but is purposefully colored to give a total decor in connection with another print layer. Before printing on the nonwoven layer 3 this is with a protective layer 5a Mistake. At the protective layer 5a it is a resin, whereby the fleece layer 3 through the protective layer 5a impregnated.

The lower decor 4 is thus on with the protective layer 5a impregnated nonwoven layer 3 applied. The lower decor 4 is applied by means of a printing process in which a pressure body with the impregnated nonwoven layer 3 has come into contact. In the next step, in this embodiment, partially an upper decor 6 applied by a digital ink jet printing process. For this, UV-curable ink was used. This ink was cured by UV light following printing. Due to the rapid curing in combination with the impregnation of the nonwoven layer 3 This prevents the ink from bleeding so that the result is a very accurate print image.

With the development of a UV-curable digital ink, it is possible to produce a razor-sharp printed image, since the drying of the UV-curable ink does not destroy the impregnate. Crosslinking occurs between the ink and the aminoplastic resin, but at the same time no dense filming of the digital print. Thus, a bond without release effect is possible, especially since an abrasion-resistant overlay on the digitally printed paper layer is possible.

Subsequently, a transparent protective layer 5b applied. In the protective layer 5b Hard particles, such as corundum, porcelain or silicon can be embedded. The protective layer 5b is usually used for components that are laid on the bottom side. The particles can in principle also be arranged on this when using an overlay. On the bottom of the main body 2 there is a return 7 ,

2 shows a planar component 1b as a variant of in 1 represented component 1a , The main difference lies in the unused protective layer 5a so that the nonwoven layer 3 not impregnated with resin. This was the lower decor 4 directly on the fleece layer 3 applied.

LIST OF REFERENCE NUMBERS

1a

component

1b

component

2

body

3

fleece layer

4

lower decor

5a

protective layer

5b

protective layer

6

upper decor

7

return

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102008033274 A1 [0004]
• DE 102007013132 A1 [0005]

Cited non-patent literature

• EN 13329 [0012]

Claims (17)

Method for producing a component for covering a floor, wall or ceiling surface, in which a non-woven layer ( 3 ) on a flat body ( 2 ) is applied, wherein before or after the application of the nonwoven layer ( 3 ) on the basic body ( 2 ) an upper decor ( 6 ) of ink by means of a digital ink jet printing process above the nonwoven layer ( 3 ) is applied. Method according to claim 1, characterized in that the upper decor ( 6 ) consists of UV-curable ink and is cured by means of UV light. A method according to claim 1 or 2, characterized in that the nonwoven layer ( 3 ) before printing with a protective layer ( 5a ). A method according to claim 1 or 2, characterized in that the nonwoven layer ( 3 ) after printing with a protective layer ( 5b ). Method according to claim 3 or 4, characterized in that the protective layer ( 5a . 5b ) is formed from a resin. Method according to claim 3 or 4, characterized in that the protective layer ( 5a . 5b ) is formed from a varnish. Method according to one of claims 4 to 6, characterized in that the protective layer ( 5b ) is provided with the abrasion resistance-increasing particles. Method according to one of claims 1 to 7, characterized in that the nonwoven layer ( 3 ) before printing with the upper decor ( 6 ) by means of a printing method in which a pressure body with the nonwoven layer ( 3 ) comes in contact with a lower decor ( 4 ) is printed. Method according to one of claims 1 to 8, characterized in that above the nonwoven layer ( 3 ) a top layer is applied as an overlay. Method according to one of claims 1 to 9, characterized in that the basic body ( 2 ) is formed from a carrier plate of a wood material, which after the application of the nonwoven layer ( 3 ) is profiled edge to form a connection geometry. Method according to one of claims 3 to 10, characterized in that on one of the nonwoven layer ( 3 ) facing away from the underside of the body ( 2 ) a return ( 7 ) is applied, wherein the protective layer ( 5a . 5b ) and the decor ( 4 . 6 ) as well as the nonwoven layer ( 3 ) and the return ( 7 ) in a common step with the main body ( 2 ) get connected. Method according to claim 11, characterized in that the individual layers ( 3 . 5a . 5b ), together with the decor ( 4 . 6 ) and the return ( 7 ) as well as the basic body ( 2 ), wherein one of the nonwoven layer ( 3 ) facing the top of the body ( 2 ) is provided with a structure. Component for covering floor, wall or ceiling surfaces, which has a flat basic body ( 2 ) in the form of a peripheral profiled carrier plate on which a nonwoven layer ( 3 ) is applied, wherein before or after the application of the nonwoven layer ( 3 ) on the basic body ( 2 ) an upper decor ( 6 ) of ink by means of a digital ink jet printing process above the nonwoven layer ( 3 ) is applied. Component according to claim 13, characterized in that the decor ( 6 ) is formed of UV-curable ink. Component according to claim 13 or 14, characterized in that one of the nonwoven layer ( 3 ) facing the top of the body ( 2 ) has a structure. Component according to one of claims 13 to 15, characterized in that the basic body ( 2 ) is provided at the edge with a profiling of a glue-free click system. Component according to one of claims 13 to 16, characterized in that the basic body ( 2 ) is a wood-based panel.

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