EP2402173B1 - Method for finishing a panel and device for implementing such a method - Google Patents

Method for finishing a panel and device for implementing such a method Download PDF

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Publication number
EP2402173B1
EP2402173B1 EP10006777A EP10006777A EP2402173B1 EP 2402173 B1 EP2402173 B1 EP 2402173B1 EP 10006777 A EP10006777 A EP 10006777A EP 10006777 A EP10006777 A EP 10006777A EP 2402173 B1 EP2402173 B1 EP 2402173B1
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EP
European Patent Office
Prior art keywords
panel
panels
characterized
method according
layer
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Application number
EP10006777A
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German (de)
French (fr)
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EP2402173A1 (en
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Flooring Technologies Ltd
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Flooring Technologies Ltd
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Priority to EP10006777A priority Critical patent/EP2402173B1/en
Publication of EP2402173A1 publication Critical patent/EP2402173A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • 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
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0041Digital printing on surfaces other than ordinary paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0041Digital printing on surfaces other than ordinary paper
    • B41M5/0076Digital printing on surfaces other than ordinary paper on wooden surfaces, leather, linoleum, skin, or flowers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/16Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
    • B44C1/165Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
    • B44C1/17Dry transfer
    • B44C1/1712Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/043Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0461Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/04Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02038Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements

Description

  • The invention relates to a method for finishing a panel, having a core of Holzwerkstoff- and arranged on an upper surface of the core primer in the form of at least one pressed to the core resin layer.
  • Laminate panels have been state-of-the-art for quite some time nowadays and can no longer be imagined today in a variety of applications, in particular as a replacement for real wood panels. A particularly large field of application consists in the cladding of walls, ceilings and floors, where from respective wall, ceiling and floor panels, the respective panel is assembled. Of course, different requirements are placed on the surface properties of such laminate panels in various fields of application. A floor panel is naturally exposed to much greater loads than, for example, a wall or ceiling paneling.
  • The large-scale production of laminate panels involves a whole series of production steps, which are largely the same for the different types of panels. It is first a support plate, for example made of a wood material such as MDF, HDF or OSB, provided and this coated with several layers optionally different materials. On a possibly pretreated surface of a wood-based panel, which was provided as the core of the panel to be produced, a decorative layer is applied. This can be done for example in the form of a printed impregnated paper. The paper can also be printed directly on top of the wood-based panel. This can be done by means of pressure rollers or a digital printer. Before the decor is printed, optionally, a primer layer can be applied to the surface of the wood-based panel. This decor must, in particular if the panel is to be used as a floor panel, be covered by at least one wear layer. This can for example consist of a paint or a synthetic resin. Advantageously, abrasion-resistant particles (eg corundum) are added, which make the surface of the finished panel more resistant to the burden of walking. The layer structure with optionally several synthetic resin layers is finally pressed in a press under pressure and temperature influence, as in EP 1 454 763 B1 to which reference is made in its entirety. Subsequently, the still large-format now coated wood-based panel is divided into individual panels. After the division into individual panels connecting means in the form of a spring and a groove with integrated locking means are attached to the side surfaces, so that two panels by means of a so-called "click-connection" connected to each other and can be locked to each other in the vertical and horizontal directions. In order to increase the realistic impression of a laminate panel, it is known to impress on the compression of the layer structure in the top of a corresponding structure to the decor (embossed-in-register). The laminate panel is thus not only visually but also haptically, for example, a real wood panel further aligned.
  • Alternatively, the coating can also be carried out with lacquer layers, which is then cured by the use of high-energy radiation, for example electron and UV radiation. Also in this case, the large-sized coated carrier plate is divided into panels only after complete curing of the applied layers.
  • In the market of laminate panels, especially the floor panels, a demand for more and more different decor variants can be observed. Not only are new wood replicas in demand, but also increasingly and stone decors and fantasy decors in various forms. The conversion of a large-scale production plant for laminate panels on a new decor, however, is relatively cumbersome, time-consuming and therefore costly. In addition, for example, in the event that the decor is placed in the form of a printed decor paper on the wood material core, decorative papers with different decors must be stored. This requires a lot of storage space and also binds unnecessarily much capital due to the large amount of decor papers to be kept.
  • If the decor is printed, for example via pressure rollers directly on the wood-based panel, a separate set of rollers must be kept for each decor, which are costly especially in the purchase. If a structure is to be embossed in the top, in addition the press plates or press plates must be costly engraved. In addition, the replacement of such press plates or press plates claimed time in which the production plant is, whereby the cost of manufacturing laminate panels increase.
  • For the above reasons, it makes only economic sense to produce relatively large numbers of laminate panels with a once selected decor before panels are produced with a different decor.
  • In addition to the demand for more and more different decor variants, however, an increasing reduction of the demanded order sizes can be observed. However, if too small quantities of laminate panels with a certain decor are in demand, they can not be produced economically. As a result, individual orders must be "collected" from the retailer or wholesaler, resulting in long delivery times for the end customer, which the latter does not accept, especially in the do-it-yourself sector. Part of the demand must therefore remain unsatisfied.
  • From the WO 2010/055429 A2 a method for producing a panel is known in which a primer is first applied to the top of a large-sized wood-based panel. The so-primed wood-based panel is optionally pressed and then divided into individual panels. Only then are the individual panels printed with the desired decor.
  • The disadvantage is that although the production system itself can be made smaller and more compact by the method described in the cited document, since not the large-format wood-based panels, but smaller panels must be printed, usually no faster delivery times small lot sizes can be achieved with individual decors , If a customer orders a small amount of panels with a desired decor, for example from a panel dealer, he will collect the incoming orders until he orders a sufficient number of panels from the panel manufacturer. This is necessary in order to keep transport costs within acceptable limits, since laminate panels are transported, for example, by large trucks, which, in order to be able to work economically, must be utilized to a certain extent. By in the WO 2010/055429 A2 Although the economy of the manufacturing process can be increased by the use of smaller plants, flexibility is not achieved, in particular with regard to the rapid delivery of small and smallest batches with individual decors. If panels are produced by a method as described in the aforementioned document, the manufacturer can react quickly and flexibly to small orders, so that these panels can reach the customer, in particular, small order quantities must be collected to make the transport worthwhile , So it does not make sense to transport two or three packages of panels separately to the customer or to the dealer. The manufactured panels must therefore be collected during manufacture until a certain scope of supply for a particular dealer is present. Only then can the transport be carried out in an economically sensible way.
  • The problem to be solved according to the invention thus consists in the fact that it is in the current situation The way in which the laminate panels required by the end customer are manufactured is, for economic reasons, not possible to satisfy even unusual customer requests within a reasonable delivery time, unless a minimum lot size is required, and even if the minimum lot size has been reached (for example, in Object area, so the equipment of large offices or hotels) a longer delivery time must be taken into account, because of course the system at the panel manufacturer must first be converted accordingly, which is not possible even in the worst order situation within a few hours or days.
  • This problem can be solved by interrupting the chain of the manufacturing process and allowing the dealer, who receives the decoration request of the end customer, to apply the decoration himself to the panels. However, the dealer can not handle and divide wood-based panels in dimensions of several meters.
  • The invention is therefore based on the object to provide a method by which the possibility is created that a dealer, the raw panels are provided, this can then be provided according to customer requirements with a decor, so that even the smallest order sizes flexible and economical can be produced and at the same time the storage and material costs are reduced.
  • The invention solves the problem by a method for finishing a panel with a core of wood-based material and arranged on an upper side of the core primer in the form of at least one pressed to the core resin layer, the panel is in a transport-safe packaging, the airtight in a film is welded, with the following steps:
  1. a) unpack a panel from the transport-safe packaging,
  2. b) selecting a special decoration from a variety of discarded decors or an individually present decoration,
  3. c) selecting a defined number of panels to be printed with the decor,
  4. d) applying a decorative layer with the selected decor to each individual panel,
  5. e) applying at least one wear layer to the decorative layer.
  • The decorative layer is advantageously printed directly on the primer or the primer. Alternatively, a decorative paper can be printed with a decor be placed on the primer or primer as a decorative layer. The at least one wear layer is advantageously made of a synthetic resin and is cured after application by compression under the influence of pressure and temperature. In particular, a structure can be introduced into the at least one wear layer.
  • Alternatively, the at least one wear layer can also consist of a lacquer which is cured after application by means of electron or UV radiation. By imprinting a structure-forming lacquer, a structure can be introduced into the at least one wear layer. Alternatively, the course of the paint disturbing means can be printed and thereby structure-forming depressions and / or increases are generated.
  • It has proven to be particularly advantageous if the application of the decorative layer and the at least one wear layer is effected by the following steps:
    • Providing the at least one wear layer on a carrier medium,
    • Printing the decorative layer on the at least one wear layer,
    • Laying the layer structure of the support medium, the at least one wear layer and decorative layer on the primer or the primer, so that the decorative layer on the primer or the primer is arranged and
    • Remove the carrier medium.
  • Subsequently, a structure can be embossed into the at least one wear layer. The structure which is introduced into the at least one wear layer advantageously corresponds to the decoration of the decorative layer in order to improve the natural impression of the imitated material. Before applying the decorative layer is the Panel advantageously cleaned.
  • A device for finishing a panel according to a method described above comprises, in particular, a printing unit for printing a decoration on the primer, the decor paper or the carrier medium coated with the at least one wear layer, an input device for inputting a selection of one in the form of electronic data Decorations deposited in a data store from a plurality of available decors by a user and an electrical controller arranged to read the selected decor from the data memory and to control the printing unit so that the selected decor is printed. Advantageously, the device has a display device via which the available decors are displayed to the user.
  • The invention is based on the idea to make the production of laminate panels, in particular for use as wall, ceiling and floor coverings more flexible, simpler and cheaper. For this purpose, it is provided that in the context of large-scale production only primed panels are produced as semi-finished products. These have a core of wood-based material, which may be formed for example as OSB, MDF or HDF. This is coated with a primer, which is pressed with the core of the wood-based panel. This results in an easily printable surface that has the required properties to ensure an excellent print image during subsequent printing. The primer in the form of a synthetic resin layer can be applied in various forms to the core of wood-based material. Conceivable, for example, the application in the form of a resin-impregnated paper, as applied directly to the top resin layer or in the form of a finish foil, which is laminated, for example, with an adhesive that may contain synthetic resin. All these applied primers lead to a particularly high surface quality. Depending on the applied to the wood-based panel primer is on the top of the wood-based panel opposite Bottom applied a coating. This can, for example, take over the function of a countermove. This is particularly necessary when a tensile force is exerted parallel to the surface of the wood-based panel on the wood-based panel during drying of the applied primer. By applying a corresponding coating on the underside of the wood-based panel, a corresponding force is exerted on the underside, so that a curvature or wringing of the wood-based panel is effectively prevented.
  • If the primer is applied, for example, in the form of a coated film which has already been cured, the application of a counterpull may be unnecessary. The coating applied to the underside can then prevent, for example, the absorption of moisture in the underside of the wood-based panel or have only optical reasons. Thus, the acceptance of a panel in the market at the end user can be increased in particular by the fact that even on the underside of the panels, which are no longer visible in the installed state, the wood-based panel acting as the core can no longer be seen.
  • After the primer on the top and the coating is applied to the underside of the wood-based panel, the layer structure is pressed. This can be done under pressure and temperature influence. This is especially necessary if at least one of the applied layers should connect to the wood-core material. If the primer is laminated in the form of an already cured film, compression under pressure is sufficient.
  • After pressing the layer structure, the still large-format, coated and compressed wood-based panel is divided into individual panels. Side surfaces of the panels are then machined to work on connecting and locking means. These connecting and locking means may consist of simple tongue and groove profiles or include more complicated profiles, with which a lock of two connected panels, for example, both in vertical as well as in horizontal direction. In addition, connecting and locking means can be worked on side edges of panels, in the still separate connection elements, which may for example consist of plastic, are used. For laying or connecting two identical panels, however, it is advantageous if connecting and locking means worked out of the panel, for example, be milled out that two identical panels can be interconnected and locked without additional fasteners.
  • The primed panels produced in this way are finally packed safe for transport. Prior to this, quality control can be carried out to ensure the highest possible quality of the primed panels.
  • Since the laminate manufacturer produces only primed panels to which no decorative layer has to be applied, the laminate manufacturer reduces both the storage costs and the material costs. There is no need to stock decor papers in different decors, or to provide embossing or embossing plates to make panels with different decors. This significantly reduces both the required storage space and the tied capital. In addition, no changeover times, as all panels have the same primer. As a result, the production plant can work more economically and the production costs are further reduced.
  • In order to ensure a particularly good printability of the panels produced in this way, the primer is in particular dyed. In particular, several colors are possible, examples being white or beige. In this case, for example, dyed papers are used as the printing base, whose color corresponds to the brightest shade in the decor to be printed. Is, as here, the applied decorative yet unknown, therefore, a white or at least very light primer is advantageous. However, any other color is also conceivable as a primer. To special effects when To achieve subsequent printing of such pre-primed panels, a structure can already be incorporated into the primer. This is advantageously done when pressing the layer structure, in particular by embossing plates or embossing rollers used.
  • However, pre-primed panels produced in this way generally have a very smooth surface. In particular, the surface is homogeneous and, if the primer is colored, good coverage. This is very important in combination with a very low defect frequency due to surface defects or dirt particles, in particular for digital printing in which the pre-primed panel is printed directly by means of a digital printer. A colored wood-based panel can at least partially take over the function of a primer.
  • Due to the very low surface roughness of the top of the panel, for example, less than 20 microns, more preferably even less than 10 microns, a very good print image is achieved during subsequent printing. The test standard for surface roughness is predominantly ISO 4287-1. When the wood-based panel or primer is colored, it is advantageous for the paint to have a brightness parameter L greater than 92, a red-green value A between -5 and +5, preferably between -2 and +2 and a yellow-blue Value B is between -15 and +15, preferably between -8 and +8. The values given describe colors in the CIELAB color space. The normative basis of this color space is DIN 6174. The color of the primer or the dyed wood-based panel should correspond to the brightest shade in the decor to be applied. If this, as in the present case, is not yet known, a particularly bright, in particular white, surface color naturally offers itself.
  • Such pre-primed panels are stored at the laminate manufacturer in a central warehouse, such as a high-bay warehouse. Previously, they can in particular be cleaned and packaged in such a way that they are printed directly in the processing plant or can be processed without the panels need to be cleaned there again. However, this only has to be maintained for a single type of panel, so that a space-intensive storage of panels with different decors, different surface structures or different surface finishes is no longer necessary.
  • The primed panels are then transported to a further processing plant. This may, for example, be a franchise operation associated with the laminate manufacturer, a hardware store, an interior decorator, a retailer or a floor publisher.
  • In this, the pre-primed panels are unpacked from the transport-safe packaging. Subsequently, a decorative layer is applied with a decor according to direct customer request to the primer or primer and covered by at least one wear layer.
  • The application of the decorative layer on the primer or the primer can be done in different ways.
  • In particular, the decorative layer can be printed directly onto the primer or the primer. The pre-primed panel passes through a printing unit, which is advantageously a digital printer. This makes it possible, in particular different designs quickly and easily to print successively on different panels without having to convert the printing unit to the new decor. The fact that only individual panels must be printed and not, as usual in the art, whole large-size wood-based panels, the printing unit can be made small and compact and thus space and cost. Alternatively, a decor paper, which can be kept in the form of large rolls, be printed with a decor and then laminated as a decorative layer on the primer or the primer.
  • In both cases, the decorative layer should be covered by at least one wear layer. The number and type of applied wear layers depends heavily on the intended location of the so decorated panels. Especially with wall and ceiling panels, it is often sufficient if the at least one wear layer covers the decorative layer wipe-resistant. However, if the printed panels are used as a floor panel, they are exposed to a significantly higher load. In this case, in particular a plurality of wear layers can be applied, to which additives are added which increase an abrasion and / or scratch resistance of the upper side of the then finished panels.
  • The at least one wear layer can consist of a synthetic resin and be cured after application by compression under the influence of pressure and temperature. During the pressing, a structure which corresponds in particular to the decoration of the decorative layer can also be embossed into the at least one wear layer so as, for example, to make the natural appearance of a real wood decoration more realistic.
  • Alternatively, the at least one wear layer may also be in the form of at least one lacquer layer, which then hardens using high-energy radiation, for example electron or UV radiation. In this case, it is also possible to apply a structure-forming lacquer over which a structure can be introduced into the at least one wear layer during curing.
  • During curing by high-energy radiation and by pressing in particular a walk-on surface of the panel can be ensured. This happens especially when the panel is to be used as a floor panel.
  • In all cases mentioned above, in the processing operation, for example in a hardware store, the decorative layer must have at least one layer of a synthetic resin or a varnish and then cured. For this purpose, a relatively high expenditure on equipment is necessary, which in addition to an increased space requirement also attracts relatively high investment costs. In addition, it may be necessary to use specialized personnel for the operation of a device for carrying out the process steps required in the further processing operation, in particular in the case of coating with synthetic resin or lacquer.
  • In a particularly simple manner, therefore, the decorative layer and the at least one wear layer can be applied to the pre-primed panel with the following method steps. On a carrier medium, for example a film, the at least one wear layer is provided. If several layers of wear are necessary, they are in unverkehrter order on the carrier medium. The wear layer, which is to form the top of the finished panel, is thus located directly on the support medium and is covered by the wear layers that lie beneath it in the finished panel. In further processing operation, different layer structures of these at least one wear layer are held on the carrier medium. The wear layer, which is intended to cover the decorative layer in the finished panel, is therefore at the very top in the layer structure on the carrier medium. This is now printed with the decor to be applied to the panel. Subsequently, the entire layer structure is placed on the primer or the primer, that now the decoration rests directly on the primer or the primer and is covered by the at least one wear layer. At the very top of the layer structure is now the carrier medium, for example the carrier foil. This layer structure is now pressed with the pre-primed panel. For this it is sufficient if pressure is exerted on the layer structure. Since the at least one wear layer, which is located on the carrier medium, is already fully cured, an effect under elevated temperature influence is unnecessary.
  • Subsequently, the carrier medium is stripped off and the decorative layer and the at least one wear layer remain on the primer or the primer. To this It is also possible to refine the primed panel without applying liquid resins and lacquers which still have to be cured. This significantly reduces both the expenditure on equipment and the investment volume. In the at least one wear layer, a structure which in particular corresponds to the decoration of the decorative layer can also be embossed in this embodiment during the compression of the layer structure.
  • A device for finishing a panel according to a method just described comprises in particular a printing unit for printing the decoration on the primer or the primer, the decorative paper or the carrier medium coated with the at least one wear layer in basically any desired color and grain and also a Input device with which a selection of a decoration can be entered, which is stored in the form of electronic data in a data memory. The apparatus also includes an electrical controller configured to read the selected decor from the data store and to drive the print engine to print the selected decor. For the customer particularly comfortable this device also includes a display device via which the available decors are displayed to the user.
  • In concrete terms, such a process can take place, for example, in a hardware store as follows.
  • A customer who needs panels for a specific room size, first receives the information, which number of panels he needs. On a display device of a device, with which the primed panel can be refined as described above, he can look at various decors that are available for selection. These decors are stored in the form of electronic data in a data memory within the device. Alternatively, the device could for example also have a drive, for example for a CD, DVD or the like. The customer can then bring a corresponding data carrier itself, on the decors in a predetermined Data format are stored. In this way it is possible for the customer to get his own individual décor printed on panels.
  • After the customer has selected a decor, he enters this selection via the input device. In addition, the customer can choose how many panels to be printed with the selected decor and what he wants to use these panels for. Depending on the intended purpose, different wear layers are applied to the panel.
  • Within the device, the desired decoration is then applied to a pre-primed profiled panel and covered with the combination of useful layers found necessary. Once these are cured, if necessary, the customer can receive and use the panels printed with their individual décor.
  • Should he notice that he has not enough panels printed or it may be necessary, for example, to replace individual worn over time panels, it is always possible to rearrange even on a device described individual panels.
  • As a result, the flexibility in the production of laminate panels is significantly increased and it is even small order quantities with different decors economically feasible to produce.
  • With the help of a drawing, the described method is explained in more detail below. It shows:
  • Figure 1-
    a schematic representation of an embodiment of the method for producing primed panels,
    FIG. 2
    a cross section through a according to the method according to FIG. 1 manufactured panel with an enlarged section of it, and
    Figure 3-
    a schematic representation of an embodiment of the method for refining a panel, as it is carried out in a further processing operation.
  • FIG. 1 shows the schematic representation of a method for producing a primed panel as a semifinished product, as can be performed at the laminate manufacturer. The processing direction is indicated by arrows. The manufacturing process begins in FIG. 1 bottom left.
  • The process begins with a large-format wood-based panel 1. The wood-based panel 1 is first supplied to a pretreatment device 2, in which the large-sized wood-based panel 1 is prepared for carrying out the method. Within this pretreatment device 2, for example, an upper side of the wood-based material panel 1 can be ground, or some other smoothing of the surface can take place. The wood-based panel 1 is prepared so that a layer of material can be applied to the top. For this purpose, the wood-based panel 1 in the pretreatment device 2, for example, additionally cleaned and / or heated. In addition, a quality assurance can take place to ensure that the surface of the wood-based panel 1 is suitable for carrying out the method.
  • After the wood-based panel 1 has been prepared in the pre-treatment device 2, it is supplied to a primer 4. In the primer 4, a primer in the form of a synthetic resin layer is applied to the top of the wood-based panel 1. This can be done, for example, by applying a liquid synthetic resin layer or in the form of a resin-impregnated paper. Alternatively, for example, a film which is coated in particular with a synthetic resin, are glued to the top of the wood-based panel 1. For this purpose, a resin containing resin can be used.
  • After the wood-based panel 1 has passed through the primer 4, it is in in FIG. 1 shown embodiment of a drying device 6 supplied. Here, if appropriate, the primer applied in the primer 4 on the upper side of the wood-based panel 1 is dried in the form of a synthetic resin layer.
  • Subsequently, the coated wood-based panel 1 passes through in FIG. 1 a short-cycle press 8, in which the wood-based panel 1 is pressed with the applied in the primer 4 primer in the form of a synthetic resin layer under pressure and temperature influence. Of course, other forms of a press, such as a belt press, conceivable. In particular, if in the primer 4, the primer in the form of a synthetic resin layer, for example by means of a film already fully cured, is optionally also a pressing only under pressure without increased temperature sufficient.
  • The pressed in the short-cycle press 8 primed wood-based panels 1 then pass through a cutting device 10, in which the large-sized wood-based panel 1 is divided into smaller panels 12. At the side edges of the panels 12 profiles are then worked, which allow a connection of two identical panels 12 together. In this case, first in a first milling device 14 Longitudinal profiles milled out of the side surfaces of the panels 12. This makes it possible to connect two identical panels 12 together along their longer side surfaces.
  • Subsequently, the panels 12 pass through a second milling device 16, in which also the short side surfaces are provided with a profile, in this case a transverse profile. Thus, identical panels 12 are connected to each other along their short side edges.
  • Subsequently, the primed and provided with connecting means panels pass through a quality assurance 18, before they are packaged safe for transport in a packing station 20.
  • When pressing the coated with the primer wood panel in a short-cycle press 8 or in another pressing device, in particular a structure can be embossed in the primer. Additionally or alternatively, a relief in the large-sized wood-based panel 1 may be provided. In order to be able to emboss a relief in the wood-based panel 1, in particular the wood-based panel 1 can be sprayed with water before the application of the primer in the primer 4. An exemplary method is in DE 10 2008 008 240 been described.
  • FIG. 2 shows a section along the line AA FIG. 1 by a pre-primed panel 12, as well as an enlarged section thereof. The panel 12 comprises a core 22 to which a primer 24 has been applied. The top of the core 22 shows a relief 26 in the form of an uneven surface of the core 22. In the primer 24, a structure 28 is impressed, which has significantly finer elements, as the imprinted in the core 22 relief 26th
  • FIG. 3 shows the schematic representation of a method for finishing a panel, as may be done in a processing plant, such as a franchisee associated with the laminate manufacturer, a hardware store, or the like. The processing direction is indicated by arrows. The processing begins in FIG. 3 bottom left.
  • The finished primed panels 102 are delivered in a transport-safe packaging 104 coming from the laminate manufacturer in further processing operation. In a first method step, the panels 102 are removed from this transport-safe packaging 104. Im in FIG. 3 In the exemplary embodiment of the method shown, the panels 102 are subsequently fed to a cleaning device 106, in which the surface of the panels 102 is cleaned of possibly adhering dirt and dust and thus prepared for the application of the decorative layer. It is also conceivable that the panels 102 have been suitably cleaned in the operation of the laminate manufacturer for later printing. These may then have been inserted into the transport-safe packaging 104 in a cleaned manner. For example, by airtight welding of the transport pack 104 in a film can be ruled out that the panels 102 must then be cleaned again before they are printed.
  • After the panels 102 have passed through the cleaning device 106, if necessary, they are aligned on an acceleration path 108 and spaced apart from one another to the desired distance. The panels 102 are then fed to a printing unit 110. Here, the surface of the panel 102 is printed with the decorative layer to be applied. For this, the printing unit 110 in the in FIG. 3 shown embodiment, three printheads 112. Depending on the desired decor, the printing unit 110 may also have more or fewer printheads 112. Connected to the printing unit 110 is an electronic data processing device 114. This has an in FIG. 3 not shown input device through which the user of a device for performing the method can select the desired decor. The electronic data processing device 114 has a display device for this purpose 116, through which the available decors, for example, stored on an electronic storage medium, the user are displayed. From this selection, the user can select the decor he wishes to have printed on his panels.
  • Im in FIG. 3 In the exemplary embodiment shown, the electronic data processing device 114 additionally has a scanner 118. If a user of the device for refining the panel 102 brings an individual décor, for example in the form of a paper-like printout, the pattern can be read into the electronic data processing device 114 via the scanner 118 and applied via the printheads 112 of the printing unit 110 to the top of the panel. The user is thus no longer limited to the pattern selection stored in the electronic data processing device 114.
  • In addition, the electronic data processing device 114 has in FIG. 3 By way of this camera 120, it is possible, for example, to photograph decors of surfaces which the customer has brought with him, but which can not be scanned, and thus read them into the electronic data processing device. Such decors can also be applied to the top side of the panel 102 via the print heads 112 of the printing unit 110. It can also be provided, for example, a CD-ROM drive, via which the customer can read a stored in a defined format on a CD-ROM decor in the data processing device 114.
  • In order for the panels 102 to remain precisely aligned by the print heads 112 during the application of the decoration, they are guided in the printing unit 110 by guide elements 122.
  • In order to ensure the best possible result, the decor proposals stored in the data memory of the electronic data processing device 114 are displayed optimizes the possible formats of the panels 102 to be printed. Individual decors of a user of the described device, which have been read into the electronic data processing device 114 via the scanner 118, the drive or the camera 120, for example, can be adapted to the panel formats. The decoration selection stored in the data memory of the electronic data processing device 114 can in particular be updated online.
  • After the upper side of the panels 102 has been printed with a décor, the panels 102 leave the printing unit 110 and are fed to a coating device 124. Im in FIG. 3 illustrated embodiment, these three application devices 126, via each of which a wear layer can be applied to the top of the panel. The applicators 126 are controlled by a second electronic data processing device 128. It has a mixing program that controls the composition of the individual wear layers. In this case, the second electronic data processing device 128 can control various storage containers 130 and mix their contents with the respective desired utility layer. In one of these reservoir 130 is the base material of each individual wear layer, which may be, for example, a synthetic resin or a paint. The further reservoirs 130 include, for example, hardener, corundum to increase the abrasion resistance of the finished coated panel and other additives that are selected depending on the intended use of the then finished panel.
  • As in the printing unit 110, various panel formats can also be processed in the coating apparatus 124. Also within the coating device 124, the panels 102 to be coated are guided over guide elements 122. A possible layer structure consists of several layers of radiation-curable lacquer. In this case, for example, two layers of an antiabrasive UV basecoat are applied with a roller system in an application amount of, for example, 35 g / m 2 onto the top surface of the panel 102 to be coated. Each applicator 126 is designed in the form of a roller system. After the two layers of the Two abrasive layers of a UV abrasive base can also be applied, each with an applicator 126, which is designed as a roller system. The application amount here is, for example, 15 g / m 2 per abrasive base layer. Finally, via a further application device 126, a layer of a UV topcoat is applied in an application rate of, for example, 35 g / m 2 . Optionally, prior to the application of each lacquer layer, the previously applied lacquer layer is cured by means of UV or electron beams. In the FIG. 3 In the embodiment shown, the various wear layers, which may in particular also consist of a synthetic resin, are applied directly one after the other without drying the wear layer previously applied by an application device 126.
  • An applicator 126 in the form of rollers can be operated both in the same and in the opposite direction. In order to coat as many panels 102 as possible in a given time, high feed rates of such applicators 126 are preferred. In particular, feed speeds of between 10 m / min and 30 m / min are suitable.
  • If paint layers are applied as wear layers by the application devices 126 in the coating device 124, these application devices 126 can also be in the form of an injection or spray painting device, a digital print head, a casting head or a vacuum. Abrasion-resistant particles, for example corundum, or other additives may be present in each applied layer. These depend on the later use of the then finished panel.
  • After the panels 102 have left the coating device 124, they are guided to a first curing device 132. Im in FIG. 3 In the exemplary embodiment shown, the wear layers applied in the coating device 124, which may for example be in the form of a lacquer, are only gelatinized by high-energy rays, for example electrons or UV rays. Subsequently In a stamping device 134, a structure is embossed into the upper side of the coated panel, that is to say the useful layers. This structure corresponds in particular to the selected decor of the decorative layer applied in the printing unit 110.
  • The embossing of the structure can be done, for example, by means of a structured roller, a structured belt or a structure-regulating paper or a structure-forming film.
  • Alternatively, an overlay paper sheet can be placed and then pressed in a short-cycle press under the action of pressure and heat. In this case, structures are provided in particular in the press plates, which impress during pressing into the top of the panel 102.
  • In particular, when using paints as wear layers and a structure-forming amount of paint can be applied by means of a digitally controlled printhead, for example. Alternatively, a means is conceivable that disturbs the course of the paint. This means can also be applied using a digitally controlled printhead. By using such a printhead, it is possible to apply the agent or the lacquer only at certain points of the surface of the panel 102 and so to create structure-forming depressions and elevations. If the structure embossed in the upper side corresponds to the decoration of the decorative layer, the panel 102 must be aligned before passing through the embossing device 134. Im in FIG. 3 In the illustrated embodiment, after passing through the embossing device 134, the panel 102 passes through a second curing device 136. Here, the optionally-gelled wear layers are completely cured so that a surface suitable for the respectively selected use of the panel 102 is produced.
  • Subsequently, the panels 102 pass through a quality assurance 138, possibly a labeling 140 or the like, if necessary, in addition also a cleaning device and are finally packed and can be taken by the customer.
  • Particularly advantageously, the electronic data processing device 114 is coupled to the second electronic data processing device 128. A customer will be given in the processing operation then for example by means of a program different choices. He can choose, for example, whether the panel 102 private or commercial, to be used in the dry or wet area, with references to various commercial use classes are given. In addition, the customer can decide whether the panel to be coated 102 will later be a floor, wall or ceiling panel. This information is important for the wear layers to be applied in the coating device 124. In a device for refining a panel, the useful layers with the required additives and additives are then automatically applied to achieve a certain degree of wear, for example AC3 according to DIN EN 13329. Painting and curing take place automatically.
  • The customer can also choose the format of the panel and the thickness of the support plate as well as the desired decor and possibly a structure to be impressed. By means of these specifications from the customer side, both the printing unit 110 and the coating device 124 can be set to the thickness and the format of the panels 102 to be coated.
  • Further options for the customer include, for example, the choice of a specific packaging. Thus, the panels can only be placed in a cardboard box or by means of a film, such as a shrink film, also protected against splashing water. In addition, the customer can decide, for example, whether he would like to take the finished panels with him or pick them up at a later time or whether they should be delivered by a third-party company. An installation option by a specialist company is also conceivable. In addition, the customer, if necessary, select at extra cost, warranty and warranty options and decide if he buys or rents the panels.
  • Within a plant for refining a panel according to the described method, the coating and the curing of the paint layers can be done automatically. Since the lacquers or resin layers used, which are applied as useful layers, can be optimized for this application, in particular with regard to their viscosity, a smooth application without increased or minimum lacquer applications at the beginning and at the end of the panels 102 to be coated can be ensured. In order to protect the connecting and locking elements already formed on the panels 102, masks may be used which prevent soiling or contamination of these connecting and locking elements. In particular, when curing lacquer layers applied by the adjustment of the radiation intensity, the adhesion of the individual layers to each other and the final curing can be realized and guaranteed. For multiple jobs, the corresponding part of the installation, ie coating device 124 and first curing device 132 and second curing device 136, can be run through multiple times.
  • For optimal use of such a system several orders can be produced directly one after the other. After an order has been completed, a fully automatic cleaning, in particular of the application devices 126 can be carried out in order to be able to provide a clean installation for the following order.
  • The method described has a number of advantages. After completion of the surface, the customer can immediately take the finished product in the desired quantity and quality. This solves in particular the problem of small quantities for the laminate panel manufacturer since he only has to manufacture one type of panel, namely pre-primed and structured panels, if necessary in different dimensions. Since the connecting and locking means are milled in this process on pre-primed panels or worked in any other form are the accumulated milling waste in particular reduced by the fact that no decor paper or overlay paper is applied to the pre-primed panels. As a result, the production costs are significantly reduced. In addition, the described method significantly reduces transport damage or transmission errors in orders, because the customer can stand directly in front of the device and enters his wishes. A transfer of an order to a laminate manufacturer is no longer necessary.
  • LIST OF REFERENCE NUMBERS
  • 1
    Wood panel
    2
    pretreatment equipment
    4
    priming device
    6
    drying device
    8th
    Short-cycle press
    10
    trimming
    12
    paneling
    14
    first milling device
    16
    second milling device
    18
    quality control
    20
    packing station
    22
    core
    24
    primer
    26
    relief
    28
    structure
    102
    paneling
    104
    transport safe packaging
    106
    cleaning device
    108
    acceleration path
    110
    printing unit
    112
    printhead
    114
    electronic data processing device
    116
    display
    118
    scanner
    120
    camera
    122
    guide element
    124
    coater
    126
    applicator
    128
    second electronic data processing device
    130
    reservoir
    132
    first curing device
    134
    embosser
    136
    second curing device
    138
    quality control
    140
    labeling

    Claims (20)

    1. Method for the refinement of a panel (102), having a core made from wood material and a grounding, arranged on the top side of the core, in the form of at least one synthetic resin layer pressed together with the core, the panel (102), being located in a transport-safe packaging (104) which is sealed, airtight, in a film, with the following steps:
      a) unpacking of a panel (102) from the transport-safe packaging (104),
      b) selection of a special decoration from a multiplicity of stored decorations or of an individually available decoration,
      c) selection of a defined number of panels (102), which are to be printed with the decoration,
      d) application of a decorative layer having the selected decoration to each individual panel (102),
      e) application of at least one wear layer to the decorative layer.
    2. Method according to Claim 1, characterized in that the multiplicity of stored decorations are stored in the form of electronic data in a data store.
    3. Method according to one of the preceding claims, characterized in that the grounding (24) is present, in particular, in the form of a synthetic resin layer applied as a liquid or in the form of a resin-impregnated paper or in the form of a glued-on film which is coated, in particular with synthetic resin.
    4. Method according to Claim 3, characterized in that the adhesive used for the film is an adhesive containing synthetic resin.
    5. Method according to Claim 3 or 4, characterized in that the grounding (24) is applied before the transport-safe packaging of the panels (102).
    6. Method according to one of the preceding claims, characterized in that the panel (102) has a coating on its underside.
    7. Method according to Claim 6, characterized in that the coating of the underside of the panel (102) is applied before the transport-safe packaging of the panels (102).
    8. Method according to one of the preceding claims, characterized in that a primer is applied to the grounding (24) before the transport-safe packaging of the panels (102).
    9. Method according to one of the preceding claims, characterized in that in that the side faces of the panels (102) are provided with connecting and locking means before the transport-safe packaging of the panels (102).
    10. Method according to one of the preceding claims characterized in that the decorative layer is printed onto the ground or primer.
    11. Method according to one of the preceding claims, characterized in that a decorative paper is printed with a decoration and is laid as a decorative layer onto the grounding or primer.
    12. Method one of the preceding claims, characterized in that the at least one wear layer consists of a synthetic resin and, after being applied, is cured by pressing under the influence of pressure and temperature.
    13. Method according to Claim 12, characterized in that a structure is introduced into the at least one wear layer during the pressing.
    14. Method according to one of the preceding claims, characterized in that the at least one wear layer consists of a lacquer and, after being applied, is cured by means of electron or UV beams.
    15. Method according to Claim 14, characterized in that, by a structure-forming lacquer being printed on, a structure is introduced into the at least one wear layer.
    16. Method according to Claim 14, characterized in that means disturbing the flow of the lacquer are printed on, structure-forming depressions and/or elevations thereby being generated.
    17. Method according to Claim 1, characterized in that the application of the decorative layer and of the at least one wear layer takes place by means of the following steps:
      - provision of the at least one wear layer on a carrier medium,
      - printing of the decorative layer onto the at least one wear layer,
      - laying of the layer build-up consisting of the carrier medium, at least one wear layer and decorative layer onto the grounding or primer, so that the decorative layer is arranged on the grounding or primer,
      - removal of the carrier medium.
    18. Method according to Claim 17, characterized in that a structure is embossed into the at least one wear layer.
    19. Method according to Claim 13, 15 or 18, characterized in that the structure matches the decoration of the decorative layer.
    20. Method according to Claim 1, characterized in that the panel (102) is cleaned before the decorative layer is applied.
    EP10006777A 2010-06-30 2010-06-30 Method for finishing a panel and device for implementing such a method Active EP2402173B1 (en)

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    EP10006777A EP2402173B1 (en) 2010-06-30 2010-06-30 Method for finishing a panel and device for implementing such a method

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    PL10006777T PL2402173T3 (en) 2010-06-30 2010-06-30 Method for finishing a panel and device for implementing such a method
    PL12008595.6T PL2572896T3 (en) 2010-06-30 2010-06-30 Device for finishing a panel
    EP10006777A EP2402173B1 (en) 2010-06-30 2010-06-30 Method for finishing a panel and device for implementing such a method
    EP16163968.7A EP3067219A1 (en) 2010-06-30 2010-06-30 Method for producing panels
    EP12008595.6A EP2572896B1 (en) 2010-06-30 2010-06-30 Device for finishing a panel
    ES12008595.6T ES2584302T3 (en) 2010-06-30 2010-06-30 Equipment to improve the finish of a panel
    ES10006777T ES2402102T3 (en) 2010-06-30 2010-06-30 Procedure for finishing a panel and equipment to perform the same
    US13/163,077 US9522567B2 (en) 2010-06-30 2011-06-17 Method for the refinement of a panel and apparatus for carrying out the same
    US15/353,281 US10226960B2 (en) 2010-06-30 2016-11-16 Apparatus for the refinement of a panel
    US16/239,196 US20190135027A1 (en) 2010-06-30 2019-01-03 Method for the refinement of a panel and apparatus for carrying out the same

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    EP16163968.7A Division EP3067219A1 (en) 2010-06-30 2010-06-30 Method for producing panels
    EP12008595.6A Division EP2572896B1 (en) 2010-06-30 2010-06-30 Device for finishing a panel

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    EP16163968.7A Pending EP3067219A1 (en) 2010-06-30 2010-06-30 Method for producing panels

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    Publication number Publication date
    EP2402173A1 (en) 2012-01-04
    EP2572896A1 (en) 2013-03-27
    US20190135027A1 (en) 2019-05-09
    US20170066282A1 (en) 2017-03-09
    PL2572896T3 (en) 2016-11-30
    EP2572896B1 (en) 2016-05-25
    ES2584302T3 (en) 2016-09-27
    US10226960B2 (en) 2019-03-12
    ES2402102T3 (en) 2013-04-29
    PL2402173T3 (en) 2013-07-31
    US20120027957A1 (en) 2012-02-02
    EP3067219A1 (en) 2016-09-14
    US9522567B2 (en) 2016-12-20

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