EP2708675A1 - Decorative panel - Google Patents

Abstract

Decorative panel comprises a plate-shaped support (110) and a decorative layer (120) provided on the support. The support has a profiling (130) at least in an edge region. The decorative layer is applied in the region of the profiling. An independent claim is also included for producing the decorative panel, comprising providing the plate-shaped support; at least partially profiling the plate-shaped support; and applying the decorative layer on the partially profiled support.

Description

The present invention relates to a decorative panel with a printed side edge and a method for producing such a panel.

For the purposes of the invention, the term decorative panel is understood to mean wall, ceiling or floor panels which have a decor applied to a carrier plate. Decorative panels are used in a variety of ways, both in the field of interior design of rooms, as well as the decorative cladding of buildings, for example in exhibition construction. One of the most common uses of decorative panels is their use as floor coverings. The decorative panels often have a decor that is intended to recreate a natural material.

Examples of such simulated natural materials are wood species such as e.g. Maple, oak, birch, cherry, ash, walnut, chestnut, wenge or even exotic woods such as panga panga, mahogany, bamboo and bubinga. In addition, many natural materials such as stone surfaces or ceramic surfaces are modeled.

So far, such decorative panels are often produced as laminates, in which on a carrier plate with a desired decor pre-printed decorative paper is applied, which in turn is then applied a so-called overlay. After optionally a Gegenzugpapier was still applied to the decorative paper opposite side of the support plate, the layer structure obtained is firmly bonded together using suitable pressure and / or heat-activated adhesive. Several such panels can be connected to each other, for example via provided in the edge regions of tongue and groove connections. It may be provided that, in addition to the corresponding groove / tongue profiles chamfers are provided, which form joints between the interconnected panels. Such joints serve decorative purposes, such as the Nachfühlung of planks (V-joints). The chamfers provided for this purpose generally have an angle of inclination between 30 ° and 60 °.

Since the corresponding profiling of the individual panels takes place after the laminate has been pressed, the chamfered edges, for example, form regions in which the decoration has been removed and the support material is visible even after the panels have been assembled. Although these areas are very small, the decoration in these areas no longer corresponds to the desired imitation, e.g. a natural material.

Taking this into account, it is the object of the present invention to provide a decorative panel which is able to overcome this disadvantage. Moreover, it is the object of the present invention to specify a method for producing such a decorative panel.

The object is achieved by a decorative panel according to claim 1. Embodiments of this panel can be found in the dependent claims and the description below.

Thus, a decorative panel is proposed which has a plate-shaped carrier and a decorative layer applied to the carrier, wherein the carrier has a profiling at least in one edge region, characterized in that the decorative layer is also applied in the area of the profiling. It may be provided that the decor simulates a natural substance.

The plate-shaped carrier of the decorative panel preferably formed of a material which is selected from the group consisting of wood, wood material, fiber material, plastic, glass, stone, ceramic, mineral material or mixtures thereof.

Wood materials in the context of the invention are in addition to solid wood materials and materials such as cross-laminated timber, glued laminated timber, hardwood plywood, veneer plywood, veneer plywood, veneer strip and bent plywood. In addition, under wood materials in the context of the invention, wood chip materials such as chipboard, extruded, coarse chipboard ( Oriented Structural Board, OSB) and chipboard wood and wood fiber materials such as Holzfaserdämmplatten (HFD), medium-hard and hard fiberboard (MB, HFH), and in particular medium density Fiber boards (MDF) and high density fiberboard (HDF). Even modern wood-based materials such as wood-polymer materials (wood plastic composite, WPC), sandwich panels of a lightweight core material such as foam, foam or paper honeycomb and thereon a layer of wood, as well as mineral, for example, with cement-bonded wood particleboard forming wood materials in the sense of the invention. Cork also represents a wood material in the context of the invention.

For the purposes of the invention, by the term fiber materials, materials such as e.g. Paper and nonwovens based on vegetable, animal, mineral or even artificial fibers to understand, as well as cardboard. Examples are fibrous materials made of vegetable fibers, in addition to papers and webs of cellulose fibers, plates of biomass such as straw, maize straw, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers. Examples of animal fiber materials are keratin based materials such as e.g. Wool or horsehair. Examples of mineral fiber materials are mineral wool or glass wool.

Plastics which can serve as carrier material are, for example, thermoplastics, such as polyvinyl chloride, polyolefins (for example polyethylene (PE), Polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or copolymers this. The plastics may contain conventional fillers, for example calcium carbonate (chalk), alumina, silica gel, quartz flour, wood flour, gypsum. Also, they can be colored in a known manner. In particular, it can be provided that the carrier material has a flame retardant.

For the purposes of the invention are meant the term stone and ceramic materials such as granite, marble, sandstone, slate, tiles, porcelain stoneware or the like. Mineral materials in the context of the invention are, for example, gypsum plasterboard, cement or concrete slabs or mixed material slabs of synthetic resin and mineral additives.

The decor is applied according to a preferred embodiment of the invention by means of pressure, preferably direct printing, on the support plate. For the purposes of the invention, the application of the decoration by means of printing techniques to a print layer previously applied to the support is also to be understood by direct printing. Such a printable layer can be formed for example by a liquid applied and then cured primer layer or a previously applied printable film, paper or nonwoven layer. The primer layer can be formed, for example, from a curable and printable polymer composition, such as polyacrylate, polypropylene, polyethylene, polyurethane acylate or the like, which is applied as a suitable prepolymer composition on the support plate and on this to a corresponding layer by suitable means such as electromagnetic radiation or heat is cured. A suitable printable film layer may for example consist of a plastic material such as polyacrylate, polypropylene, polyethylene, polyurethane acrylate or the like, which can be applied to the profiled carrier. suitable Papers are, for example, those which are also used as starting material for pre-printed decorative papers. Suitable nonwoven layers are, for example, those based on vegetable, animal, mineral or even artificial fibers.

On the at least in one edge region profiled plate-shaped support or applied to this printable layer a desired decor can be applied by means of suitable printing techniques. Examples of suitable printing techniques for the direct printing of decorative panels are high-pressure processes, such as, for example, flexographic printing, offset printing, gravure printing or throughprinting methods, such as screen printing. In particular, it may be provided that the printing of the decor by means of digital printing method, such as inkjet method, is applied.

According to a further embodiment of the invention, it may be provided that the decorative panel has a wear and / or cover layer over the decorative layer. A wearing and / or covering layer in the sense of the invention is a layer applied as an outer finish, which in particular protects the decorative layer from wear or damage by dirt, moisture or mechanical effects such as abrasion. It may be provided that the wear layer hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, alumina (corundum), zirconium oxide or mixtures thereof, to increase the wear resistance of the layer. The wear and / or cover layer can be applied for example as a liquid composition on the printed with the decor carrier and cured on this. It may be provided that the hard material in an amount between 5 wt .-% and 40 wt .-%, preferably between 15 wt .-% and 25 wt .-% in the wear layer composition is included. The hard material preferably has an average particle diameter between 10 μm and 250 μm, more preferably between 10 μm and 100 μm. As a result, it is advantageously achieved that the Wear layer composition forms a stable dispersion and segregation or settling of the hard material in the wear layer composition can be avoided. To form a corresponding wear layer, it is provided in one embodiment of the invention that the hard material-containing and radiation-curable composition in a concentration between 10 g / m ² and 250 g / m ² , preferably between 25 g / m ² and 100g / m ² applied becomes. In this case, the application can be applied for example by means of rollers, such as rubber rollers or by means of pouring devices. In a further embodiment of the invention, it may be provided that the hard material is not present in the composition at the time of application of the wear layer composition, but is scattered as particles onto the applied wear layer composition and this is subsequently cured. Likewise, it can be provided that the wear and / or cover layer is placed as a pre-produced overlay on the printed carrier and connected to this by pressure and / or heat.

According to a further embodiment of the invention, it can be provided that the wear and / or cover layer has a surface texture substantially matching the decor of the decorative layer. Under a matching with the decor surface structuring is to be understood that the surface of the decorative panel has a haptic perceptible structure, which corresponds in shape and pattern of the applied decor, so as to obtain a true to the original reproduction of a natural material also in terms of haptics. It can be provided that the carrier plate already has a structuring and alignment of a printing tool for applying the decoration and the support plate to each other in dependence of the detected by means of optical methods, for example structuring of the support plate. For aligning the pressure tool and the support plate to each other, it may be provided that a necessary relative to the alignment relative movement between the pressure tool and the support plate by a displacement of the support plate or done by a shift of the pressure tool. According to a further embodiment of the invention, it is provided that a structuring of the decorative panels takes place after the application of the wear and / or cover layer. For this purpose, it can preferably be provided that a curable composition is applied as a wear and / or cover layer and a curing process takes place only to the extent that only partial hardening of the wear and / or cover layer takes place. In the thus partially cured layer, a desired surface structure is impressed by means of suitable tools, such as a hard metal structural roll or a stamp. The embossing is done in accordance with the applied decor. In order to ensure sufficient conformity of the structure to be introduced with the decor, provision may be made for the carrier plate and the embossing tool to be aligned with one another by corresponding relative movements. Following the introduction of the desired structure into the partially cured layer, a further hardening of the now structured wearing and / or covering layer takes place.

With regard to the method, the object of the invention is achieved by a method according to claim 8.

• Bereitstellen eines plattenförmigen Trägers;
• zumindest teilweises Profilieren des plattenförmigen Trägers;
• Aufbringen einer Dekorschicht auf den zumindest teilweise profilierten Träger.

Thus, a method for producing a decorative panel is proposed, comprising the method steps:

• Providing a plate-shaped carrier;
• at least partially profiling the plate-shaped carrier;
• Applying a decorative layer on the at least partially profiled carrier.

Due to the inventive application of the decoration only after the at least partial profiling of the carrier, a removal or damage of the decoration in the course of profiling is advantageously avoided.

In a partial profiling of the decorative panel not all to be provided in the final panel profiles are introduced, but only a part of the profiles to be provided, while other profiles are introduced in a subsequent step. For example, it may be provided that the decorative profile to be provided in a panel, e.g. a chamfer is introduced in one step, while the functional profile, e.g. Tongue / spring is introduced in a subsequent step.

The application of the decorative layer on the at least partially profiled carrier can be done for example by means of an already pre-printed paper, which is also applied to the profiled portion of the carrier. In a particularly preferred embodiment of the method, however, it is provided that the decorative layer is applied by means of direct printing on the carrier. For the purposes of the invention, the application of the decoration by means of printing techniques to a print layer previously applied to the support is also to be understood by direct printing. Such a printable layer can be formed for example by a liquid applied and then cured primer layer or a previously applied printable film, paper or nonwoven layer. On the at least in one edge region profiled plate-shaped support or applied to this printable layer is applied by means of suitable printing techniques, the desired decor. Examples of suitable printing techniques for the direct printing of decorative panels are high-pressure processes, such as, for example, flexographic printing, offset printing, gravure printing or throughprinting methods, such as screen printing. In particular, it may be provided that the printing of the decor by means of digital printing method, such as inkjet method, is applied.

In this case, it can be provided, in particular, that the print original used for the printing is distortion-compensated in the area of the profiling of the panel. Distortion compensation means in the sense of the invention which, due to the deviation of the profiling from the surface plane of the carrier, eg at a chamfer edge, caused distortion of the printed image is compensated by adjusting the artwork to the deviation. It may be provided, for example, that the compensation of the distortion by means of adjustment of the pixel spacing, the pixel size and / or the ink application depending on the intended edge profile of the finished decorative panel. In the case of printing by means of digital printing, the triggering of the print head can be effected as a function of the distortion to be compensated, so that the print head is deflected beyond the profiled area, for example, and the color output is adapted to the profile.

According to a preferred embodiment of the method according to the invention, this has, after the application of the decorative layer on the additional step of applying a wear and or cover layer. In this case, the wear and / or cover layer can be applied to the printed substrate in the previously described manner as a prefabricated overlay or else in liquid form and then cured.

According to a further embodiment of the method, this has the additional method step of introducing into the wear and / or cover layer a structuring which essentially corresponds to the decor of the decorative layer. In this case, the introduction of the structuring can take place in the manner previously described for the corresponding panel.

According to a further particularly preferred embodiment of the invention, it can be provided that the plate-shaped support is provided as a large plate, which is divided into a plurality of decorative panels in a subsequent operation. A large plate according to the invention is a carrier whose dimensions exceed the dimensions of the final decorative panels by a multiple and which is divided in the course of the manufacturing process in a corresponding plurality of decorative panels, for example by punching, sawing, laser or water jet cutting. In this case, it is possible, for example, that prior to the application of the decorative layer of the carrier provided as a large panel, the joints to be provided in a final panel composite (such as V-joints) are milled into the carrier, at least the decorative layer is applied to the carrier profiled in this way and the carrier is then divided at least in the profiled areas. Depending on the type of division, such as sawing, laser cutting or water jet cutting, it can preferably be provided that the required cutting allowance is taken into account in the introduced profile.

According to a further embodiment of the method, it is provided that an additional profiling step takes place at least in a partial region of the edges of the decorative panel substantially parallel to the surface of the panel. Thereby, for example, the functional profiles to be provided, e.g. Tongue and groove, are introduced into the panel. In the case of providing the carrier as a large plate, such an additional profiling step preferably takes place after the division into individual panels. If the carrier is already provided in the desired dimension of the single panel, such an additional profiling step can also take place simultaneously with the introduction of the other profiles, such as a chamfer.

• Fig. 1 zeigt einen Querschnitt eines erfindungsgemäßen profilierten Dekorpaneels;
• Fig. 2 zeigt einen Querschnitt einer erfindungsgemäß in einen als Großplatte bereitgestellten Träger einzubringenden Profilierung;
• Fig. 3 zeigt eine weitere Ausgestaltung eines Querschnitts einer erfindungsgemäß in einen als Großplatte bereitgestellten Träger einzubringende Profilierung.
• Fig. 1 zeigt einen Querschnitt eines erfindungsgemäßen profilierten Dekorpaneels 100. Das Dekorpaneel 100 weist einen plattenförmigen Träger 110 und eine auf den Träger aufgebrachte Dekorschicht 120 auf. In einem Randbereich weist der Träger 100 eine Profilierung 130 auf, welche aus einem dekorativen Bereich 131 und einem funktionalen Bereich 132 gebildet wird. Der dekorative Bereich 131 kann dabei aus eine Fase der Kante bestehen, welche zusammen mit einer Fase eines mit dem Dekorpaneel verbundenen zweiten Paneels eine V-förmige Dekorfuge ausbilden kann. Der funktionale Bereich 132 der Profilierung kann aus einer Nut und/oder einer Feder gebildet werden, über welche Paneele miteinander verbunden werden können. Das erfindungsgemäße Dekorpaneel 100 weist im Gegensatz zu den bisher bekannten Paneelen zumindest auch im Bereich der dekorativen Profilierung 131 eine Dekorschicht 120 auf. Auf die Dekorschicht 120 kann eine Verschleiß- und/oder Deckschicht 140 aufgebracht werden, welche sich auch zumindest über die Profilierung 131 erstreckt.
• Fig. 2 zeigt einen Querschnitt einer erfindungsgemäß in einen als Großplatte 200 bereitgestellten Träger 110 einzubringenden Profilierung 133. Die eingebrachte Profilierung 133 weist dabei eine Y-Form auf. Dabei wird die Fußbreite der Y-förmigen Profilierung 133 derart ausgewählt, dass sie eine Schnittzugabe 150 umfasst, welche die bei einem Zerteilen der Großplatte 200 in Einzelpaneele 101/102 entstehende Schnittbreite berücksichtigt. Der Kopf der Y-förmigen Profilierung 133 bildet die für die spätere V-förmige Dekorfuge zwischen miteinander verbundenen Paneelen verantwortliche Fase 131 der Kanten aus.
• Fig. 3 zeigt eine weitere Ausgestaltung eines Querschnitts einer erfindungsgemäß in einen als Großplatte 200 bereitgestellten Träger 110 einzubringenden Profilierung 133. Die eingebrachte Profilierung 133 weist dabei eine Y-Form mit einer Verbreiterung im Fußbereich auf. Die Fußbreite der Y-förmigen Profilierung 133 ist derart ausgewählt, dass sie neben einer Schnittzugabe 150 auch eine funktionale Profilierung 132 umfasst, welche beispielsweise eine an einer Kante der Dekorpaneele 101/102 vorgesehene Nut ausbildet. Der Kopf der Y-förmigen Profilierung 133 bildet die für die spätere V-förmige Dekorfuge zwischen miteinander verbundenen Paneelen verantwortliche Fase 131 der Kanten aus.

The invention will be further explained with reference to figures.

• Fig. 1 shows a cross section of a profiled decorative panel according to the invention;
• Fig. 2 shows a cross section of an invention to be introduced in a carrier provided as a large plate profiling;
• Fig. 3 shows a further embodiment of a cross section of an invention to be introduced in a carrier provided as a large plate profiling.
• Fig. 1 shows a cross section of a profiled decorative panel 100 according to the invention. The decorative panel 100 has a plate-shaped support 110 and a decorative layer 120 applied to the support. In an edge region, the carrier 100 has a profiling 130, which is formed from a decorative region 131 and a functional region 132. The decorative area 131 can consist of a chamfer of the edge, which together with a chamfer of a second panel connected to the decorative panel can form a V-shaped decorative groove. The functional region 132 of the profiling can be formed from a groove and / or a spring, by means of which panels can be connected to one another. In contrast to the previously known panels, the decorative panel 100 according to the invention has a decorative layer 120 at least also in the area of the decorative profiling 131. On the decorative layer 120, a wear and / or cover layer 140 may be applied, which also extends at least over the profiling 131.
• Fig. 2 shows a cross section of a present invention in a provided as a large plate 200 carrier 110 profiling 133. The introduced profiling 133 in this case has a Y-shape. Here, the foot width of the Y-shaped profile 133 is selected such that it includes a cutting allowance 150, which takes into account the resulting when dividing the large plate 200 in individual panels 101/102 cutting width. The head of the Y-shaped profiling 133 forms the chamfer 131 of the edges responsible for the later V-shaped decoration groove between interconnected panels.
• Fig. 3 shows a further embodiment of a cross section of a present invention in a provided as a large plate 200 carrier 110 profiling 133. The introduced profiling 133 has a Y-shape with a broadening in the footer. The foot width of the Y-shaped profile 133 is selected such that, in addition to a cutting allowance 150, it also comprises a functional profiling 132, which For example, forms a provided on an edge of the decorative panels 101/102 groove. The head of the Y-shaped profiling 133 forms the chamfer 131 of the edges responsible for the later V-shaped decoration groove between interconnected panels.

Claims (14)

Decorative panel, comprising a plate-shaped carrier and a decorative layer applied to the carrier, wherein the carrier has a profiling, at least in one edge region, characterized in that the decorative layer is also applied in the profiling. Dekorpaneel according to claim 1, wherein the decorative layer replicates a natural material. Decorative panel according to one of the preceding claims, wherein the plate-shaped support is formed of a material which is selected from the group consisting of wood, wood material, fiber material, plastic, glass, stone, ceramic, mineral material or mixtures thereof. Decorative panel according to one of the preceding claims, wherein the decorative layer can be applied to the carrier by means of printing technology. Decorative panel according to claim 5, wherein the decorative layer can be applied by means of digital printing and / or screen printing. Decorative panel according to one of the preceding claims, wherein it has a wear and / or cover layer applied to the decorative layer. Decorative panels according to claim 6, wherein the wear and / or cover layer has a surface texture substantially matching the decor of the decorative layer. Method for producing a decorative panel, comprising the method steps: - Providing a plate-shaped carrier; - at least partially profiling the plate-shaped carrier; - Applying a decorative layer on the at least partially profiled carrier. Process according to claim 8, comprising the additional process step: - Applying a wear and / or cover layer on the decorative layer. Process according to claim 9, comprising the additional process step: - Introducing a structuring substantially matching the decor of the decorative layer in the wear and / or cover layer. Method according to one of claims 7 to 10, wherein the plate-shaped support is provided as a large plate, which is divided into a plurality of decorative panels in a subsequent operation. A method according to claim 11, wherein an additional profiling step takes place at least in a partial region of the edges of the decorative panel substantially parallel to the surface of the panel. Method according to one of claims 7 to 12, wherein the printing master used for printing is distortion-compensated in the area of the profilings. The method of claim 13, wherein the compensation of the distortion by adjusting the pixel spacing, the pixel size and / or the color order depending on the intended edge profile of the finished decorative panel.

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