EP2566700B1 - Method and apparatus for producing three-dimensional surfaces - Google Patents

Description

State of the art

The invention relates to a method and an apparatus for producing three-dimensional surfaces.

A method or a device for this purpose are already known from WO 2008/155276 A2 known. In the known method, an image is printed on a decorative paper by means of a digital printing machine, which is passed as an endless web below the digital printing press. Subsequently, the decorative paper provided with the image is applied together with an overlay paper to a carrier element and pressed with this. It is essential here that the desired structure is embossed or pressed into the carrier element by the pressing of the composite consisting of the carrier element, the decor paper and the overlay paper. For this purpose, the pressing device must have a correspondingly formed pressing plate or die. The production of such matrices or press plates is relatively expensive, expensive and requires a relatively long time, especially for small batches or small piece sizes of the support element. Moreover, it is disadvantageous that the carrier paper or overlay paper used, for example as a result of changing moistures or temperatures, is subject to variations in length or width, which is very difficult or only with relatively high outlay to coincide with the printed image of the die to bring is.

In addition, from the EP 1 017 555 B1 The applicant is aware of a method for producing a template having a three-dimensional structure, which is used for producing surfaces, in particular surfaces of melamine resin, in the manufacture of laminate panels. This is on the surface of the laminate plate, a structured surface is produced in that the web-shaped matrix is brought into coincidence with the surface of the laminate board and pressed with it. The structure of the die transfers to the surface of the laminate. After the template has been removed, it may optionally be reused, and it is also known from the cited document to provide the layer or structure of the matrix with color pigments which combine with the surface of the laminate plate during curing or pressing diffused.

A method for producing three-dimensional surfaces according to the preamble of claim 1 and claim 2 is known from the document US 2005/014005 A1 known.

Disclosure of the invention

Starting from the illustrated prior art, the invention has the object, a method and a device for producing three-dimensional surfaces such that this is economically applicable to relatively small batches, has high flexibility and high accuracy and has haptic favorable properties , This object is achieved in a method and a device for producing a three-dimensional surface having the features of the independent claims. The invention is based on the idea to form the image generated by at least one digital printing machine as a three-dimensional structure, so that it is possible to dispense with the production of expensive semi-finished products, for example specially shaped embossing dies or the like. It has surprisingly been found that such three-dimensional surfaces can be produced by means of in particular a plurality of digital printing machines arranged one behind the other so that the image or the three-dimensional structure can be connected directly or indirectly to the carrier element. As a result, it is possible to produce, in particular, haptically easily perceivable surface structures which produce the impression, for example, of a real wood surface or the like. Here, the number of superimposed layers is not limited in principle. For example, it is quite possible with a typical layer thickness of 15 μm, for example To arrange six such layers one above the other, resulting in a haptic clearly recognizable structure.

When using radiation-curable, in particular UV-curable, solvent-free and water-free pigmented binders, the production process is accelerated or simplified insofar as the layers can be applied with very short drying times or within a relatively compactly arranged device.

With particular advantage, it is considered that the structure is formed directly on a carrier element, in particular a plate, such as e.g. a furniture panel or a floor element can be applied. This eliminates the need for elaborate dies or tools for the formation of the three-dimensional structure, which allows the economic use or economic production of relatively small batches. Furthermore, by dispensing with additional intermediate elements, such as e.g. a backing paper or the like, the production additionally simplified or made more economical.

In an alternative embodiment of the invention, it is provided that the structure is applied to a sheet-like or film-like web. Such a web is used for example for the coating of furniture and may optionally be provided on the side facing the furniture with a connecting layer.

A use of a device for generating three-dimensional surfaces is defined in claim 8. Advantageous developments of the method according to the invention or the use according to the invention of a device for producing three-dimensional surfaces are given in the respective subclaims.

With particular advantage is considered that the gloss level of each layer on the drying or curing of the pigmented binders, in particular their drying time, can be adjusted. As a result, the visual impression for a viewer can be additionally improved, so that the impression arises that the three-dimensional surface, for example, of a natural Material, such as a wood veneer exists. This is particularly advantageous in the case of laminate flooring, for example, which should give the viewer or user the impression of a real wooden floor.

In addition, if desired, additional desired properties of the surface, e.g. an increased hardness to form, it is also provided in a further embodiment of the invention that the structure of further processing steps, in particular surface processing steps, is subjected.

When using a device for producing three-dimensional surfaces is proposed in the dependent claim 9 for forming a relatively compact and high-performance device that a plurality of digital printing machines are provided that the printing presses are arranged in the conveying direction of the support member one behind the other and that each printing press one Drying device is assigned.

Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings.

Fig. 1

einen vereinfachten Längsschnitt durch eine Vorrichtung zum Erzeugen einer dreidimensionalen Oberfläche in einem plattenförmigen Trägerelement,

Fig. 2

einen Schnitt durch das Trägerelement gemäß Fig. 1 zur Darstellung seiner dreidimensionalen Struktur und deren Aufbau,

Fig. 3 bis Fig. 5

die Erzeugung einer dreidimensionalen Struktur unter Verwendung elektrisch leitfähiger Farben in verschiedenen Bearbeitungsschritten und

Fig. 6 bis Fig. 10

einen Schnitt durch ein Trägerelement mit einer Struktur, die unter Verwendung elektrisch nichtleitender Farbe entstanden ist, wobei die dreidimensionale Oberfläche einer Oberflächenbehandlung unterzogen wird, ebenfalls während verschiedener Bearbeitungsschritte.

These show in:

Fig. 1

a simplified longitudinal section through an apparatus for generating a three-dimensional surface in a plate-shaped support member,

Fig. 2

a section through the support element according to Fig. 1 to show its three-dimensional structure and its structure,

FIG. 3 to FIG. 5

the production of a three-dimensional structure using electrically conductive colors in various processing steps and

FIG. 6 to FIG. 10

a section through a support member having a structure which has been formed using electrically non-conductive paint, wherein the three-dimensional surface is subjected to a surface treatment, also during various processing steps.

The same components or components with the same function are provided in the figures with identical reference numerals.

In the Fig. 1 a device 10 for generating a three-dimensional surface 1 on a support element 5 is shown. In the carrier element 5 is in the in the Fig. 1 illustrated embodiment to a plate, such as a furniture plate or a floor element, in particular a floor element as part of a laminate floor. It is also within the scope of the invention that the carrier element 5 is a sheet-like or foil-like web, as used for coating furniture workpieces, wherein the web can have a connecting layer on the side assigned to the furniture workpiece. In any case, the end product thus has a three-dimensional surface 1.

The carrier element 5 is conveyed in the direction of the arrow 12 by means of a conveying device 11 which is in particular continuously driven and not shown in detail.

In the exemplary embodiment, the device 10 comprises four devices, each designed as digital printing presses 13 to 16, in particular each a plurality of printer nozzle units 18. Furthermore, each of the digital printing presses 13 to 16 in the conveying direction (arrow 12) of the support member 5 is followed by a particular controllable UV drying device 20 at.

By means of the device 10 described so far is on the top or surface 1 of the support member 5 is a three-dimensional, in the Fig. 2 applied structure 2 shown. The structure 2 has in the in the Fig. 2 illustrated embodiment, four equally thick print layers 22 to 25. However, the number of print layers 22 to 25 may also be larger or smaller, depending on the number of digital printing machines used 13 to 16. In the embodiment, the four print layers 22 to 25 are each formed the same thickness, but they may also have different thicknesses. As a typical layer thickness of the print layers 22 to 25, this has a thickness of about 15 .mu.m. The experiments carried out in the context of the invention were made by means of a piezoelectric inkjet printer of the "LEC-330" series from Roland. In this case, UV-curing binders were used, in which pigmented inks or colors were added. The solvent-free inks were applied using the ink-jet process. In addition, it is mentioned that the easiest way to set the thickness of the print layers 22 to 25 is via the size of the color drops used (droplet size).

According to the invention, it is provided that the printing layers 22 to 25 are successively produced or formed by means of the device 10 or the digital printing machines 13 to 16, by first producing the first printing layer 22 by means of the first digital printing machine 13. This print layer 22 is then dried by means of the first drying device 20 assigned to the printing press 13, whereupon the second print layer 22 is subsequently applied by means of the second printing press 14. It is essential that at least one, preferably all print layers 22 to 25 produce an overall image. In this case, it can also be provided that only the lowermost layer 22 facing the carrier element 5 generates the image, while the other layers generate the three-dimensional structure 2.

It is also essential that the degree of gloss of the respective print layer 22 to 25 can be influenced by curing by means of the drying devices 20, in particular by the drying time. In this case, gloss levels between glossy and dull are adjustable by varying the drying time, wherein a longer drying time is accompanied by an increase in the gloss level.

The three-dimensional surface 1 or its structure 2 produced so far by means of the printing presses 13 to 16 can subsequently be subjected to further treatment or processing steps which serve, for example, to cure the surface 1. Such surface treatments may, for example, also consist in the use of different paint systems which may subsequently be applied to the surface 1. Furthermore, the surface 1 can be pressed by means of an overlay or coated with different films. Furthermore, an electron beam treatment or other mechanical processing (for example, polishing or matting) of the surface 1 is conceivable.

In the Fig. 3 to 5 the various processing steps for producing a galvanized surface 30 are shown. Here is in the Fig. 3 initially the untreated support member 31 shown, which subsequently ßend according to Fig. 4 is printed in the embodiment with three layers 32 to 34 of electrically conductive paint according to the method previously described. Subsequently, according to the Fig. 5 formed by the layers 32 to 34, three-dimensional surface 30 is provided with a galvanic layer 35 or coated. As coatings, for example chromium layers, such as matt chrome or hard chrome, in question. It is also possible to use nickel or copper with subsequent mechanical or galvanic aftertreatment.

In the Fig. 6 to 10 are shown processing steps, as they serve to produce a three-dimensional surface 40 on a support member 41 using electrically non-conductive paint. This is accordingly of the Fig. 7 First, a layer 42 of electrically non-conductive ink printed on the support member 41. Subsequently, according to the Fig. 8 the gaps of the layer 42 completely galvanized with a material 43. In a further manufacturing step according to the Fig. 9 Then the printing ink (layer 42) is removed and last accordingly Fig. 10 the remaining structure either reworked or completely electroplated or coated with a layer 45 without aftertreatment.

The device 10 described so far or the method described so far for the production of a three-dimensional surface 1 can be modified or modified in many ways without deviating from the idea of the invention. This consists in particular in the direct production of a three-dimensional structure 2 on a surface 1 by means of at least one digital printing press 13 to 16. Thus it can be provided, for example, by the addition of abrasive agents in the printing ink (or directly into a gloss varnish) a wear-resistant Surface, even without finishing, to produce.

LIST OF REFERENCE NUMBERS

1

three-dimensional surface

2

structure

5

support element

10

contraption

11

Conveyor

12

arrow

13

press

14

press

15

press

16

press

18

Print nozzle unit

20

UV drying device

22

print layer

23

print layer

24

print layer

25

print layer

30

surface

31

support element

32

layer

33

layer

34

layer

35

electroplated layer

40

surface

41

support element

42

layer

43

material

45

layer

Claims (9)

1. A method for producing three-dimensional surfaces (1; 30; 40) on a carrier element (5; 31; 41), in which method a plurality of layers (22 to 25; 32 to 34; 42) arranged one above the other produce a structure (2), the layers (22 to 25; 32 to 34; 42) being applied in succession to the carrier element (5; 31; 41) by means of at least one digital printing machine (13 to 16), and at least one of the layers (22 to 25; 32 to 34; 42) serving to produce an image and containing pigmented inks or dyes in a binder,
   characterised in that
   the inks or dyes are UV-curable, and the structure (2) is applied directly to the carrier element (5), which is in the form of a furniture board or flooring element.
2. A method for producing three-dimensional surfaces (1; 30; 40) on a carrier element (5; 31; 41), in which method a plurality of layers (22 to 25; 32 to 34; 42) arranged one above the other produce a structure (2), the layers (22 to 25; 32 to 34; 42) being applied in succession to the carrier element (5; 31; 41) by means of at least one digital printing machine (13 to 16), and at least one of the layers (22 to 25; 32 to 34; 42) serving to produce an image and containing pigmented inks or dyes in a binder,
   characterised in that
   the inks or dyes are UV-curable, and the structure (2) is applied to a sheet- or film-like web for coating a furniture workpiece, wherein the web is provided on the side opposite the structure (2) with a connecting layer for connection to the furniture workpiece, if necessary.
3. The method according to claim 1 or 2,
   characterised in that
   the image is produced by means of the first layer (22; 32) applied to the carrier element (5; 31; 41).
4. The method according to claim 1 or 2,
   characterised in that
   the image is produced by means of at least two layers (22 to 25; 32 to 34; 42) applied one on top of the other.
5. The method according to any one of claims 1 to 4,
   characterised in that
   a solvent- and water-free binder, where necessary with the addition of abrasive agent, is used as the binder.
6. The method according to any one of claims 1 to 5,
   characterised in that
   the gloss level of each layer (22 to 25; 32 to 34; 42) is set by means of the drying of the pigmented binder, in particular the drying time.
7. The method according to any one of claims 1 to 6,
   characterised in that
   the structure (2) is subjected to further processing steps, in particular surface-processing steps.
8. The use of a device (10) for producing three-dimensional surfaces (1; 30; 40) using the method according to any one of claims 1 to 7,
   wherein at least one digital printing machine (13 to 16) produces a printed image, wherein at least one, preferably a plurality of digital printing machines (13 to 16) are provided, which apply a plurality of layers (22 to 25; 32 to 34; 42) of a three-dimensional structure (2) to a carrier element (5), and wherein at least one of the layers (22 to 25; 32 to 34; 42) produces an image.
9. The use according to claim 8,
   characterised in that
   a plurality of digital printing machines (13 to 16) are provided, the printing machines (13 to 16) are arranged one behind the other in the transport direction (12) of the carrier element (5), and each printing machine (13 to 16) is assigned a drying device (20), which can in particular be controlled.

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