DE102022103652A1 - Three-dimensional structured decorative element - Google Patents

Abstract

The present invention relates to a method for producing a three-dimensionally structured decorative element (10). A surface (26) of the carrier layer (22) is structured 3D and the decoration (52) is then applied thereto. A reference geometry (34) that can be read out is generated on the surface (26) and provides information about the position (36; 37; 50) of the structure (26). The reference geometry (34) is then read out and used to control a subsequent coating process (56) in such a way that the decoration (52) is applied to the 3D structuring of the surface (26) of the carrier layer (22) as intended.
The invention also relates to a three-dimensionally structured decorative element (10) produced in this way and a corresponding production system (12) with a control unit (20).

Description

The present invention relates to a method for producing a three-dimensionally structured decorative element and a three-dimensionally structured decorative element. The invention also relates to a production system for producing a three-dimensionally structured decorative element and a corresponding control unit.

Three-dimensionally structured decorative elements are used in many areas and can be produced in a variety of ways.

For example, from the EP 2 373 494 B1 discloses a process for producing coated panels in which a plastic layer is first applied to a substrate and then a relief is applied to a surface of the plastic layer.

The EP 3 381 710 A1 describes another method for producing coated panels. In this case, an outer layer with a relief is produced by creating a pattern of cutouts using a material-repellent agent. The EP 3 640 041 A1 describes a process in which similar cutouts are produced by a printing process.

The CN 105835589B further describes a method for producing a coated sheet material with a relief. It is manufactured by locally increasing or decreasing a volume of a surface layer.

The WO 2021/116447 A1 also discloses a method for producing a structured anti-wear film. A top layer containing paint is structured using a digital printing process.

The EP 2 313 281 B1 also describes a method for producing a decoratively printed surface. A liquid base coat is applied, dried and then coated using digital inkjet printing.

From the EP 3 932 684 A1 also discloses a method for producing a relief on a substrate. Here the relief is made by sublimation.

The EP 3 875 248 A1 describes another method for producing a three-dimensional structure on a surface. A relief is applied to the surface and provided with a cover.

Three-dimensionally structured decorative elements are also increasingly finding their way into the area of floor coverings. A decorative coating that imitates a natural surface is often required here. An example of this is wood decors, in which, for example, a natural grain or a knot approach is to be reproduced three-dimensionally and colored in an appealing way.

Such decors pose great challenges for the production technology, particularly in the field of digital printing, in which the decor is printed directly onto a carrier layer from a digital data set.

Conventionally, therefore, a decor carrier, such as a film, paper or the like, is often printed with a decor and then a carrier layer is covered with the decor carrier. The carrier layer, which is initially coated with a 2D decoration in this way, is then three-dimensionally mechanically deformed or structured in order to produce a relief. Finally, the 3D decorative element produced in this way is often surface-coated for sealing purposes, e.g. to protect a floor covering from wear and tear.

Structuring usually takes place with a forming tool, for example with a press plate or a press roller. The 3D structure of the 3D decoration to be produced is reproduced in the forming tool. The 3D structure is then pressed or embossed into the carrier layer coated with the 2D decoration under high pressure and high temperature. So that such a 3D structuring or embossing can be arranged to match the 2D decoration, the forming tool has, for example, a so-called register mark. The pre-printed 2D decor then also has such a register mark. For correct structuring, the register marks of the forming tool and the 2D decor must then be brought into overlap, so that the 3D structuring is embossed on the 2D decor as intended. Conventionally, the alignment of the forming tool and the decoration can be done manually, for example, by laying it down, or else electronically, for example by optoelectronic registration.

The US 2021/0245544 A1 describes, for example, a method for producing a relief by printing and forming. A substrate is provided with a digital print and then a three-dimensional structure is produced with a rolling device.

Conventional production, comprising placing decoratively printed print films and subsequent structuring, is often carried out in clocked manufacturing processes, for example using a press plate with 3D structuring or in continuous flow processes, e.g. using a press roller with 3D structuring.

In such flow processes, production speeds of the decoratively coated substrate and the downstream structuring must be adapted to one another or synchronized accordingly. This often leads to problems, since hardly foreseeable effects such as jamming, slippage, transverse and longitudinal contraction of the material can occur in the structuring process. Such effects occur particularly frequently with materials of higher density and influence the production speed of the structuring process, which can fluctuate irregularly as a result. Such fluctuations have a negative effect on the decor image.

A further problem consists in the fact that pressure is exerted on the surface with the decoration which determines the aesthetic impression during the structuring and additional heat is possibly introduced. In the case of, for example, paper or film as a decorative carrier, this often leads to material distortion. Color changes can also occur as a result of heat and pressure.

Conventionally, there are therefore also alternative methods based on a temporary addition of material to a carrier layer. In this case, for example, a lacquer layer can be applied to the carrier layer, which is selectively removed again for structuring.

However, such methods, in which the additional material has to be removed again chemically or mechanically, are expensive and also ecologically questionable. In order to produce an aesthetically perceptible decorative image with sufficient structure depth, a relatively large amount of structure paint has to be applied, a large amount of which has to be chemically or mechanically removed again.

Finally revealed the EP 3 640 042 A1 yet another method in which a relief is made using masking.

However, such techniques are very expensive due to the additional masking and unmasking process.

The present invention is therefore based on the object of proposing a method for producing a three-dimensionally structured decorative element that requires little effort and is easy to control. In addition, a high quality of the decorative element should be achieved and the production should be environmentally friendly.

The object is solved by the subject matter of the independent patent claims 1, 9, 11 and 12. Preferred embodiments of the present invention result from the features mentioned in the subclaims and furthermore from the present disclosure as a whole.

• -Bereitstellen eines Trägerelements;
• - Herstellung einer dreidimensional strukturierten Oberfläche an dem Trägerelement mit einer Strukturierungseinrichtung;
• - Herstellung wenigstens einer Referenzmarke an dem Trägerelement mit einer Markierungseinrichtung, wobei die hergestellte Referenzmarke mit der hergestellten dreidimensional strukturierten Oberfläche zumindest bezüglich ihrer Position auf dem Trägerelement in einer vorbestimmten geometrischen Beziehung steht; und danach
• - Aufbringen eines Dekors auf die dreidimensional strukturierte Oberfläche mit einer Beschichtungseinrichtung, wobei anhand der Referenzmarke zumindest eine Relativposition der dreidimensional strukturierten Oberfläche zur Beschichtungseinrichtung ermittelt und verwendet wird, um das Dekor in einer vorbestimmten geometrischen Beziehung zur dreidimensional strukturierten Oberfläche aufzubringen.

A first aspect of the invention relates to a method for producing a three-dimensionally structured decorative element, comprising the following steps:

• - providing a carrier element;
• - Production of a three-dimensionally structured surface on the carrier element with a structuring device;
• - Production of at least one reference mark on the carrier element with a marking device, wherein the reference mark produced is in a predetermined geometric relationship with the three-dimensionally structured surface produced, at least with regard to its position on the carrier element; and then
• - Applying a decoration to the three-dimensionally structured surface with a coating device, at least one relative position of the three-dimensionally structured surface to the coating device being determined and used on the basis of the reference mark in order to apply the decoration in a predetermined geometric relationship to the three-dimensionally structured surface.

In other words, a 3D structuring of a surface of the carrier layer is carried out first and the decoration is then applied to it. A readable reference geometry is generated on the surface, which provides information about the position of the structure. The reference geometry is then read out and used to control a downstream coating process in such a way that the decoration is applied as intended to the 3D structure produced on the surface of the carrier layer.

The three-dimensionally structured decorative element produced in the method of the invention can preferably be a three-dimensionally structured floor covering element. In principle, however, other types of decorative elements can also be produced. The carrier element can then, for example, comprise a floor covering blank, which can consist, for example, of wood, wood-based materials, polymers and combinations of these materials, such as, for example, PVC. For example, it can be sought that the three-dimensionally structured decorative element to be produced has a natural wood surface a three-dimensionally structured grain in a certain way. For example, prominent cracks or knots in the wood surface can be reproduced here, the natural appearance of which comes from a combination of three-dimensional structuring and coloring. Then, for example, the structuring, comprising the cracks, the knots and the reference mark, is first introduced into the surface of the carrier element, for example embossed. The decoration is then applied to the structuring, it being important for the natural appearance that a crack or knot approach is given a characteristic coloration, for example color graded or shaded. Accordingly, specific color areas of the decor are to be applied to specific areas of the structure. For this purpose, the reference mark is read, which has a defined relative position to, for example, the crack and the knot in order to apply the appropriate color areas to the crack and the knot.

The method of the invention thus allows the necessary components “3D structuring” and “coloring” of the three-dimensionally structured decoration to be combined with one another as intended, precisely and with little effort. Since the relative position of the 3D structuring and the coating device is known at all times via the detection of the reference mark, the process is very reliable, very easy to control and, in particular, robust against random influences that can change the relative position.

Due to the high level of process reliability, hardly any rejects are produced here. Furthermore, only temporarily applied additives can be dispensed with. The method of the invention is thus also particularly ecological and economical.

All materials that can be structured three-dimensionally come into consideration as materials for the carrier element. Materials such as wood, plastics such as vinyl materials (PVC, LVT) or also laminates, for example including such materials, are particularly preferred here. Materials such as ceramics or stone can also be considered.

The surface can be structured three-dimensionally, for example with a relief, a texture or the like. Depending on the material, different structuring methods can be used and a correspondingly designed structuring device can be used. Forming processes, such as embossing or pressing, are preferably used as structuring processes for deformable materials such as wood or plastic. This can also be supported by using heat. For hard materials such as ceramics or stone, cutting processes are preferred, such as milling, water or sand blasting or laser processing.

In the context of the invention, the reference mark can also be referred to as a register mark. It can be produced before the structuring, simultaneously with it or also afterwards. Correspondingly, the marking device can be integrated with the structuring device or provided downstream. The register mark is preferably produced simultaneously with the structuring, since the method is particularly efficient in this way and at the same time a very precise, intended geometric relationship can be achieved between the reference mark and the three-dimensionally structured surface. It is advantageous to coordinate data transmitted to the structuring device, for example milling files for deep engraving, and data transmitted to the coating device, for example separate print files. The optimal position of the three-dimensionally structured surface and the decoration relative to one another is particularly preferably defined by means of a fiducial mark in the data. A fiducial mark is an identical reference mark contained in at least two corresponding data sets of the structuring device and the coating device, which ensures that the decoration and the three-dimensionally structured surface are superimposed as intended when the decorative element is produced on the basis of these data sets, so that the fiducial marks or reference marks lie on top of each other. For example, this reference mark can be stamped into the surface together with the structuring. However, the reference mark can also be produced before or after the structuring. This can then preferably take place very shortly before or after the production of the structuring, preferably without intermediate transport of the carrier element. Such a procedure is appropriate, for example, if the structuring is produced by means of laser processing. Since the laser beam always works at specific points, the structuring and the reference mark are necessarily produced sequentially if several lasers are not used. The structuring and the reference mark are then preferably produced in one setting. However, intermediate transport of the carrier element can also take place. A detection and optionally a measurement of the already produced structuring then preferably takes place first, in order to then produce the reference mark to match it. Such a detection can also be combined with other quality assurance steps, purely as an example via image recognition of the structuring produced. The detection and, if necessary, the measurement can be repeated if necessary after the reference mark has been produced, in order to check whether the reference mark produced is actually in the predetermined geometric relationship to the structure. A very precise production of the reference mark can also be ensured in this way.

The reference mark can include, for example, a crosshair, a triangle of threads or also a crosshair with different edge lengths. However, it can also include only one hole or be designed as a see-through register.

The reference mark produced is in a predetermined geometric relationship with the structure, at least with regard to its position on the carrier element. Such a relationship can preferably include a defined distance between the reference mark and the structuring in the longitudinal and transverse directions on the carrier element. Since the structure has a known shape, the position of the reference mark is in the predetermined geometric relationship with the structure as a whole and with each of its structural elements. From the defined distance of the reference mark and the structuring as a whole, it is therefore possible to deduce a distance between the reference mark and individual structural elements.

The structuring can be a pattern that is periodically repeated on the carrier element (in the sense of an endless structuring). With regard to its predetermined geometric relationship, the position of the reference mark can also only relate to, for example, one period of the pattern. A reference mark is then preferably produced for each period, which is then recognized on the coating device, for example for printing the respective period. A period length can therefore preferably be matched to the process of the coating device, in which mostly only a limited working space is available in which the period can be printed.

The reference mark is preferably also in a predetermined geometric relationship with the structure with regard to its orientation on the carrier element. Such a relationship can preferably include a parallel alignment of the reference mark and the structuring on the carrier element.

For the inclusion of such geometric relationships, reference marks with a clear orientation are preferred, for example an isosceles triangle of threads, the length of which is greater than its width, or a crosshair with different edge lengths.

In this way, an accuracy in the fitting of the decor to the structuring can be further increased.

The reference mark can also be in a predetermined geometric relationship with the structure with regard to its size on the carrier element. For example, the reference mark can represent a size scale compared to the structuring. The size scale can be represented both longitudinally and transversely on the support element and even in depth. For example, the reference mark can be embossed into the carrier layer at a defined depth, so that conclusions can be drawn about the depth of the structuring.

All of this can be used in addition to controlling the application of the decoration to the three-dimensional structure, so that the accuracy in fitting the decoration to the structure is further increased and accidental interference can be compensated even better.
In principle, the reference mark can also be integrated into the structure. The structuring can then, for example, deviate locally from, for example, the otherwise natural wood grain in favor of the geometric manufacturing accuracy required for the reference mark.

In particular, after the reference mark has been produced, the decoration is applied to the structure in a likewise predetermined geometric relationship thereto. This ensures the intended optical interaction of 3D structuring and coloring. For this purpose, the reference mark is recognized and at least the relative position to the structuring is deduced from this, so that the decoration can be applied congruently to the structuring, for example. In particular, it can advantageously be achieved that specific color areas of the decoration can be applied very precisely to specific areas of the structuring provided for this purpose and accidental interference can be compensated for.

Analogously to what was said above, conclusions can also be drawn, for example, about the relative orientation or also about the size of the structuring in order to further increase the accuracy of the process.

For this purpose, the coating device preferably comprises a suitable detection system, particularly preferably an optical measuring system such as a camera or a laser measuring system. For the sake of completeness, it should be noted that, purely in principle, a tactile measuring system can also be used, with which the reference mark is scanned.

The determined relative position and, if required, also the determined relative orientation are particularly preferably evaluated in at least one of their time derivatives. It is thus particularly advantageous to draw conclusions about a relative speed or also a relative acceleration of the structuring compared to the coating device, as a result of which disturbing influences such as speed fluctuations on the structuring device can be compensated for particularly well.

This is particularly advantageous, for example, in order to adapt a manufacturing speed of the coating device to a manufacturing speed of the upstream structuring device or to synchronize the manufacturing speeds in a manufacturing flow process.

Depending on the material of the carrier layer, a wide variety of coating processes can be considered, such as spraying, imprinting or conventional printing plates or printing rollers. In principle, the process must be suitable for applying color or color pigments to the structure as intended. However, digital printing processes are particularly preferred.

Jet printing methods are preferably used as digital printing methods. These are suitable for deformable materials such as wood or plastic, as well as for hard materials such as ceramics or stone.

On the basis of the present disclosure, the person skilled in the art is able to independently select suitable structuring and coating methods, taking into account the specific material of the carrier element, the complexity of the structuring to be produced and the corresponding decoration to be produced.

It should also be noted that flexible structuring and coating devices can also be used. For example, a structuring device can be used that includes an embossing tool changing system in order to produce different structures. This is also possible with blasting methods, for example. In combination with a digital printing device, there are special advantages here, since different three-dimensionally structured decorative elements can be produced flexibly.

Following the coating, the surface of the decorative element can optionally also be coated or sealed in order to ensure protection against wear, for example in the case of a floor covering.

In a preferred embodiment of the method of the invention, it is provided that the structuring device and the coating device are connected to one another in the sense of flow production and that a relative speed of the three-dimensionally structured surface to the coating device is also determined from the determined relative position and used to adapt a production speed of the coating device to a Adjust production speed of the structuring device.

Since random effects such as material jams, slippage or transverse and longitudinal contraction of the material can occur in the structuring process, the production speed at the structuring device can fluctuate. At the same time, the application process on the coating device represents a process step that is particularly relevant to quality. Due to the synchronization of the production speeds described, the structuring device is, so to speak, leading for the control of the flow production. Unexpected changes in the material flow can thus be effectively compensated for at the coating device.

Flow production can be clocked or continuous, with the reference mark being detected in front of or at the coating device and in particular the speed of the reference mark (and thus of the decoration) controlling the coating process. For clocked flow production, for example, embossing plates are also suitable for producing the structuring, whereas embossing rollers are preferred in continuous flow production.

In a further preferred embodiment of the method of the invention, it is provided that the structuring device and the coating device are connected to one another in the sense of continuous production in a material buffer, with a production speed on the coating device and a production speed on the structuring device being decoupled and also a relative speed from the determined relative position of the three-dimensionally structured surface to the coating device is determined and used to control the production speed of the coating device.

Since random effects such as material jams, slippage or also transverse and longitudinal contraction of the material can occur in the structuring process, the production speed at the structuring device can fluctuate, as mentioned above. At the same time, the application process on the coating device, as mentioned, represents a process step that is particularly relevant to quality. Due to the buffering of the material that now takes place after the structuring device, unexpected changes in the material flow can thus be effectively compensated for on the coating device and the production speed of the coating device can, for example, be based on a feed speed of the Materials can be controlled from the material buffer.

The buffered flow production can be clocked or continuous, with the reference mark being detected before or at the coating device and in particular the speed of the reference mark (and thus of the decoration) controlling the coating process. For example, embossing plates are also suitable for producing the structuring in clocked throughput production, whereas embossing rollers are preferred in continuous throughput production.

In principle, the carrier element can be in the form of piece material or can also be supplied to the method of the invention as endless material.

In a preferred embodiment of the method of the invention, it is provided that the structuring device produces the three-dimensionally structured surface by reshaping and/or cutting.

A forming process, for example an embossing process, is preferred here since there is no loss of material and the process can be carried out very quickly and precisely. For some materials such as stone, however, this is not possible. A separation process is then used.

In a preferred embodiment of the method of the invention, it is provided that the coating device applies the decoration by digital printing, since this printing technique can be used particularly flexibly.

In a preferred embodiment of the method of the invention, it is provided that the reference mark and the three-dimensionally structured surface are produced simultaneously.

The marking device can then preferably be integrated in the structuring device. Particularly preferably, the structuring and the production of the reference mark then take place together by reshaping.

In an alternative preferred embodiment of the method of the invention, it is provided that either the reference mark is produced before the three-dimensionally structured surface and the reference mark is measured at least once before the three-dimensionally structured surface is produced, or that the three-dimensionally structured surface is produced before the reference mark and the three-dimensionally structured surface is measured at least once before the reference mark is produced.

This is particularly useful for methods in which simultaneous structuring and production of the reference mark is difficult, such as in blasting methods or when separate structuring and marking devices are to be used for other reasons. This is also useful if material is to be transported between the structuring and production of the reference mark.

According to the invention, the reference mark or the three-dimensionally structured surface is measured at least with respect to its position, so that the respective other element (reference mark/structuring) can be positioned in a defined manner relative thereto.

The relative positioning can be invariably predetermined or flexibly fixed. In the latter case, the defined relative positioning is expediently transferred to the coating device, so that it can conclude where the structuring is located after detecting the reference mark. All of this can be implemented, for example, via a common control unit.

To further increase the accuracy, the reference mark or the structuring can also be measured with regard to its orientation or size in order to orient or dimension the respective other element in a defined manner relative thereto.

In a preferred embodiment of the method of the invention, in which the reference mark and the three-dimensionally structured surface are preferably produced simultaneously, it is provided that a reference structure resulting from the three-dimensionally structured surface is at least also used as the reference mark. The reference mark is particularly preferably produced simultaneously with the three-dimensionally structured surface and a reference structure resulting from the three-dimensionally structured surface is used as the reference mark.

All reference structures contained in the three-dimensionally structured surface that are sufficiently geometrically determined come into consideration for this purpose. The required accuracy of such reference structures results from the required accuracy in the positioning of the decoration relative to the three-dimensionally structured surface by means of the downstream coating device. By way of example, the reference structure can be a horizontal and a vertical groove (representative of cracks in the wood, for example), which run sufficiently straight and perpendicular to one another to serve as a reference mark. As already mentioned above, such reference structures can also be specifically planned into the design of the three-dimensionally structured surface.

In such configurations of the method, the structuring device can also be regarded as a marking device, since it produces both the three-dimensionally structured surface and the reference structure or reference mark contained therein.

Furthermore, reference structures of the three-dimensionally structured surface can also only serve as part of a reference mark, with another part of the reference mark still being produced separately with the marking device.

A further aspect of the invention relates to a three-dimensionally structured decorative element, produced in a method according to the invention in accordance with the present disclosure.

This is preferably a floor covering element.

A further aspect of the invention relates to a production system designed to carry out a method according to the invention in accordance with the present disclosure.

The production system of the invention is preferably designed and set up to carry out the method according to the invention.

A further aspect of the invention relates to a control device designed and set up to carry out a method according to the invention in accordance with the present disclosure.

The control unit of the invention is preferably designed and set up to control a production system according to the invention. The control unit is particularly preferably able to control the structuring device, the marking device, the coating device and any detection or measuring systems and to process their data.

With regard to possible configurations of the three-dimensionally structured decorative element according to the invention and the production system and control unit according to the invention, it is noted that all features of these devices or products of the invention disclosed in the description of the method according to the invention are also disclosed as their independent features in possible configurations. Analogously, any method features disclosed in relation to the named devices or products according to the invention are also disclosed as independent features of possible configurations of the method according to the invention.

In principle, all features that are disclosed herein with reference to a specific embodiment can also be combined with other embodiments of the invention. This also applies in particular to individual features, as long as it is not explicitly pointed out here that there is an inseparable functional-technical connection between certain features, which must be maintained in order to implement the invention.

• 1 den Ablauf eines erfindungsgemäßen Verfahrens anhand eines erfindungsgemäßen Produktionssystems;
• 2 Referenzmarken in unterschiedlichen Varianten; und
• 3 ein erfindungsgemäßes dreidimensional strukturiertes Dekorelement.

The invention is explained below by way of example using exemplary embodiments and schematic drawings. Here show:

• 1 the sequence of a method according to the invention using a production system according to the invention;
• 2 reference marks in different variants; and
• 3 an inventive three-dimensionally structured decorative element.

1 shows the sequence of a method according to the invention for producing a three-dimensionally structured decorative element 10, purely by way of example using a production system 12 according to the invention.

The production system 12 includes a structuring device 14, a marking device 16 and a coating device 18, which will be discussed in more detail later. The production system 12 also includes a control unit 20, which is designed and set up here in accordance with the exemplary production system 12 to control the production system 12 for carrying out the method according to the invention. For this purpose, the control unit 20 exchanges data 60 with the respective devices 14, 16, 18 or other subsystems of the production system 12 as required.

The method according to the invention for producing the three-dimensionally structured decor element ment 10 comprises a first step in which a carrier element 22 is provided. In this example, the carrier element 22 is, for example, a floor covering blank that consists of a vinyl material or a laminate comprising vinyl material. Correspondingly, in this exemplary embodiment, a three-dimensionally structured floor covering element 24 is produced as a three-dimensionally structured decorative element 10 . The carrier element 22 is provided here as an example of endless material and is fed to the structuring device 14 in the direction indicated by the thick arrow at the left-hand end of the decorative element 10 .

In a second step, a three-dimensionally structured surface 26 is then produced on the carrier element 22 in the structuring device 14. In this exemplary embodiment, the structuring device 14 produces the three-dimensionally structured surface 26 by forming, for example. For this purpose, in this embodiment variant, it comprises a roller 28 with which the three-dimensionally structured surface 26 is embossed into the carrier element 22 . In other embodiment variants, the three-dimensionally structured surface 26 can be produced by means of an embossed press plate. In this example, the three-dimensionally structured surface 26 corresponds to a natural wood surface, which has typical cracks 30 or knots 32 (cf 3 ).

In this exemplary embodiment, a third step is carried out at the same time as the second step, but this can also be carried out at different times in other exemplary embodiments. In the third step, a reference mark 34 (cf 2 and 3 ) stamped into the carrier element 22.

The reference mark 34 produced is in relation to the three-dimensionally structured surface 26 produced with respect to its position 36 (cf 3 ) on the support member 22 in a predetermined geometric relationship.

Before this is discussed in more detail, the reference mark 34 itself should be based on 2 be explained more clearly. 2 shows three exemplary variants of the reference mark 34. On the left, for example, a reference mark 34 as crosshairs with different edge lengths 38 is illustrated. Due to the different edge lengths 38, this reference mark 34 can also be assigned an unambiguous orientation. A reference mark 34 is illustrated in the middle as a crosshair with the same edge lengths 40 . Since this always looks the same at 90° intervals, such a reference mark 34 can only give a limited orientation. In flow processes such as the one present here, however, this is often sufficient since the orientation of the carrier element 22 can only change in small areas during the flow of material anyway. right in 2 a reference mark 34 is also illustrated as an isosceles triangle 42, which also has a clear orientation.

Following the explanation of 1 and 3 , in this exemplary embodiment reference mark 34 is assumed to be crosshairs with the same edge lengths 40 . This is also in the top left 3 recognizable. The predetermined geometric relationship between the position 36 of the reference mark 34 and the position 37 of the three-dimensionally structured surface 26 relates to each element of the three-dimensionally structured surface 26, such as the crack 30 or the branch attachment 32. In other words, the position 36 of the Reference mark 34 can be clearly described in its own coordinate system of the three-dimensionally structured surface 26 and therefore recursively also each position 39 of any element of the three-dimensionally structured surface 26, starting from the position 36 of the reference mark 34.

In 3 is shown as an example that the position 36 of the reference mark 34 on the carrier element 22 has, for example, a defined distance from the branch attachment 32 in the longitudinal direction 44 and transverse direction 46 on the carrier element 22.

The three-dimensionally structured surface 26 can be present as a periodically repeating pattern in the sense of an endless structuring. For example, can 3 be interpreted in such a way that a section 45 of the periodic pattern or the three-dimensionally structured surface 26 is shown therein, which repeats in the longitudinal direction 44, for example, every three following sections (not shown further). In the example shown, the reference mark 34 therefore lies within the section 45 of the pattern associated with it.

In the present example, the method runs as flow production, in the direction indicated by the thick arrow at the left end of the decorative element 10 . The roller 28 thus produces the three-dimensionally structured surface 26 with the reference mark 34 continuously or in a clocked manner, here as an example in periodically recurring sections 45 according to FIG 3 on the carrier element 22.

After leaving the structuring device 14, such a section 45 of the carrier element 22 passes with the produced three-dimensional structured surface 26 and the reference mark 34 produced in a fourth step, a detection system 48 of the production system 12. The detection system 48 is implemented here as an example as an optical measuring system in the form of a camera 49 and can also exchange data 60 with the control unit 20. The recognition system 48 detects the reference mark 34 (cf. 2 ) and can thereby determine a relative position 50 of the reference mark 34 to the coating device 18. The detection system 48 can also be integrated directly into the coating device 18 . Since the position 36 of the reference mark 34 relative to each element of the three-dimensionally structured surface 26 is known, the determined relative position 50 of the reference mark 34 to the coating device 18 also provides the relative position of each element (e.g. reference numbers 30 and 32) of the three-dimensionally structured surface 26 to the coating device 18. For the branch attachment 32, the calculation of the relative position to the coating device 18 would be simplified here, for example the relative position 50 of the reference mark 34 to the coating device 18 added vectorially to the position 36 of the reference mark 34 relative to the branch attachment 32.

In a fifth step, a decoration 52 is then applied to the three-dimensionally structured surface 26 using the coating device 18. The decoration 52 corresponds to a color layer equivalent in FIG 3 recognizable three-dimensionally structured surface 26. The relative position 50 of the three-dimensionally structured surface 26 to the coating device 18 is determined using the reference mark 34 and used to apply the decoration 52 in a predetermined geometric relationship to the three-dimensionally structured surface 26. The predetermined geometric relationship includes in particular that the matching color areas of the decoration 52 are applied to the corresponding elements (e.g. reference numerals 30 and 32) of the three-dimensionally structured surface 26, for example to color the crack 30 and the branch 32 naturally. It should be noted that the reference mark 34 in 3 shown for better illustration. If required, however, this can be overlaid by the decoration 52 so that it is no longer visible on the finished decoration element 10 .

the inside 3 The state shown thus shows the intended combination of the three-dimensionally structured surface 26 and the decoration 52, which are congruently connected to one another.

A digital printing process is preferably used for applying the decoration 52 .

It has already been mentioned that the structuring device 14 and the coating device 18 are connected to one another in the sense of flow production.

A relative speed 54 and, if required, a relative acceleration 55 of the three-dimensionally structured surface 26 to the coating device 18 can also be determined with particular advantage from the determined relative position 50 . The relative speed 54 can be used to adapt a production speed 56 of the coating device 18 to a production speed 58 of the structuring device 14 (this applies analogously to relative accelerations).

For this purpose, the detection system 48 as in 1 shown with several, e.g. two, cameras 49, 51, in order to improve the recognition accuracy. However, the detection system 48 can also only be integrated in the coating device 18, e.g. with the camera 51. The spatial proximity to the coating device 18 significantly improves the possibility of synchronizing the production speed 56 on the coating device 18 and the production speed 58 on the structuring device 14.

In principle, however, the detection system 48 can also be arranged only between the coating device 18 and the structuring device 14 or between the marking device 16 and the coating device 18 .

It should also be noted that the in 1 The arrangement of the detection system 48 shown is also particularly well suited for other process characteristics in which the three-dimensionally structured surface 26 is produced in front of the reference mark 34.

In such an alternative embodiment of the method, it is preferred that the three-dimensionally structured surface 26 is measured at least once before the reference mark 34 is produced, so that the reference mark 34 is positioned as intended with respect to the three-dimensionally structured surface 26 .

In such methods, the marking device 16 can be used as a separate device, e.g. between the in 1 Camera 49 shown and the coating device 18 may be provided in order to measure the three-dimensionally structured surface 26.

The coating device 18 then also has the camera 51 for detecting the reference mark 34.

In principle, after the decoration 52 has been produced, a seal 62 can optionally be applied to the decoration 52 in order to protect the floor covering element 24 against wear, for example. For this purpose, the production system 12 can include an optional sealing device 64 .

Reference List

10

three-dimensional structured decorative element

12

production system

14

structuring facility

16

marking device

18

coating device

20

control unit

22

carrier element

24

flooring element

26

three-dimensional structured surface

28

roller

30

Crack

32

branch base

34

reference mark

36

Position (of the reference mark)

37

Position (of the three-dimensional structured surface)

38

Crosshairs with different edge lengths

39

position (of the branch base)

40

Crosshairs with equal edge lengths

42

isosceles triangle

44

longitudinal direction (of the support element)

45

Section (of the three-dimensional structured surface)

46

transverse direction (of the support element)

48

detection system

49

camera

50

Relative position (reference mark for the coating device)

51

camera

52

decor

54

Relative speed (reference mark for the coating device)

55

Relative acceleration (reference mark for the coating device)

56

production speed (of the coating device)

58

production speed (of the structuring device)

60

Data

62

sealing

64

sealing device

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• EP 2373494 B1 [0003]
• EP 3381710 A1 [0004]
• EP 3640041 A1 [0004]
• CN 105835589B [0005]
• WO 2021116447 A1 [0006]
• EP 2313281 B1 [0007]
• EP 3932684 A1 [0008]
• EP 3875248 A1 [0009]
• US20210245544A1 [0014]
• EP 3640042 A1 [0020]

Claims (12)

Method for producing a three-dimensionally structured decorative element (10), comprising the following steps: - Providing a carrier element (22); - Production of a three-dimensionally structured surface (26) on the carrier element (22) with a structuring device (14); - Production of at least one reference mark (34) on the carrier element (22) with a marking device (16), wherein the produced reference mark (34) with the produced three-dimensionally structured surface (26) at least with regard to its position (36) on the carrier element (22) is in a predetermined geometric relationship (44; 46); and then - Application of a decoration (52) to the three-dimensionally structured surface (26) with a coating device (18), wherein at least one relative position (36; 37; 50) of the three-dimensionally structured surface (26) to the coating device (18 ) is determined and used to apply the decoration (52) in a predetermined geometric relationship to the three-dimensionally structured surface (26). procedure after claim 1 , characterized in that the structuring device (14) and the coating device (18) are connected to one another in the sense of flow production and that from the determined relative position (36; 37; 50) a relative speed (54; 55) of the three-dimensionally structured surface (26 ) to the coating device (18) is determined and used to adapt a production speed (56) of the coating device (18) to a production speed (58) of the structuring device (14). Method according to one of the preceding claims, characterized in that the structuring device (14) and the coating device (18) are connected to one another in the sense of continuous production in a material buffer, with a production speed (56) at the coating device (18) and a production speed (58 ) are decoupled from the structuring device (14) and from the determined relative position (36; 37; 50) a relative speed (54; 55) of the three-dimensionally structured surface (26) to the coating device (18) is also determined and used to calculate the production speed ( 56) of the coating device (18). Method according to one of the preceding claims, characterized in that the structuring device (14) produces the three-dimensionally structured surface (26) by reshaping and/or cutting. Method according to one of the preceding claims, characterized in that the coating device (18) applies the decoration (52) by digital printing. Method according to one of the preceding claims, characterized in that the reference mark (34) and the three-dimensionally structured surface (26) are produced simultaneously. Procedure according to one of Claims 1 until 5 , characterized in that either the reference mark (34) is produced before the three-dimensionally structured surface (26) and the reference mark (34) is measured at least once before the three-dimensionally structured surface (26) is produced, or that the three-dimensionally structured surface (26 ) is produced before the reference mark (34) and the three-dimensionally structured surface (26) is measured at least once before the reference mark (34) is produced. Method according to one of the preceding claims, characterized in that a reference structure resulting from the three-dimensionally structured surface (26) is at least also used as the reference mark (34). Three-dimensionally structured decorative element (10), produced in a method according to one of Claims 1 until 8th . Three-dimensionally structured decorative element (10). claim 9 , characterized in that it is a three-dimensionally structured floor covering element (24). Production system (12), designed to carry out a method according to one of Claims 1 until 8th . Control unit (20), designed and set up to carry out a method according to one of Claims 1 until 8th with a production system (12). claim 11 .

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