EP3851294A1 - Method and device for providing laminate panels with individualized decorative elements - Google Patents

Abstract

The invention relates to a method for providing laminate panels provided with individualized decors, in particular wood-based laminate panels, for a party B, in particular an end user, comprising the steps: provision of at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, the laminate panel blank being one with a Coating as a printing primer and at least one backing pressed carrier plate and with connecting elements inserted into the panel edges, printing of at least one decoration selected individually by the end user on the laminate panel blank in digital printing; and pressing at least one thermoplastic film onto the printed decoration as a wear layer

Description

The present invention relates to a method for providing laminate panels provided with individualized decorations, a laminate panel produced using this method, and a device for carrying out this method.

description

Laminate panels have become indispensable for a wide range of applications, especially as a replacement for real wood panels. A particularly large area of application is the cladding of walls, ceilings and floors, where the respective cladding is put together from corresponding wall, ceiling and floor panels. Of course, different requirements are placed on the surface properties of such laminate panels in different areas of application. A floor panel is naturally exposed to much greater loads than, for example, wall or ceiling cladding.

The large-scale production of laminate panels comprises a whole series of production steps that are largely the same for the various areas of application of laminate panels. First, a carrier board, for example made of a wood material such as chipboard, MDF, HDF or OSB, is provided and this is coated with several layers of possibly different materials. A decorative layer is applied to an optionally pretreated surface of a wood-based panel. This can take place, for example, in the form of a printed impregnated paper. The decor can also be printed directly onto the top of the wood-based panel. This can be done by means of pressure rollers or a digital printer. Before the decor is printed on, a primer layer can optionally also be applied to the surface of the wood-based panel. This decoration, in particular if the panel is to be used as a floor panel, must be covered by at least one abrasion-resistant protective layer, for example made of paint or resin. The layer structure is then pressed in a press under the influence of pressure and temperature. Subsequently, the still large-format, now coated, wood-based panel is divided into individual panels, which are provided with locking means in the form of a tongue and a groove on the side surfaces, so that the panels can be connected easily.

A major topic in many product areas of wood-based panels today is individualization. The customer often wants a product that is tailored to his or her individual wishes and / or needs. The customer is also prepared to accept a higher price for this additional service.

New technologies such as digital printing or 3D printing are developing possibilities for manufacturers to realize both small quantities (keyword: number of pieces 1) and new production possibilities outside of the classic production lines. Many products are affected by these tendencies, including floor coverings. These were usually produced in large quantities per decor in the manufacturers' factories. The decors were mostly developed by suppliers (designers, printers, etc.) and then distributed to the industry. A collection was then created by the flooring manufacturers from a certain number of decors and made available to the flooring dealers and thus also to the end customers for selection.

In the past, there was little or no room for customization in this approach. It was also not possible for the end customer to participate. This essentially applied to all floor coverings, including laminate flooring.

In recent years, however, there have been increasing attempts to satisfy the desire for individualized floor coverings. Often, however, there was still a somewhat complicated procedure to complain about, since the end customer had to order a desired individualized floor covering from the manufacturer via the dealer. This not only led to sometimes very long delivery times but also to possible problems if the floor covering actually delivered differs significantly from a sample or a digitized image. Usually the range of possible designs is also reduced so that the manufacturer does not have to deal with too much variety. Another problem is that very small delivery quantities often have to be sent. This leads to relatively high transport costs per square meter of product.

In order to remedy this problem, a procedure according to the EP 2 572 896 B1 used, in which coated floor boards are printed with a decor at the point of sale (POS) and then varnished. However, this process has the disadvantage that the paints used are UV-curing systems (acrylates) which, because of the photoinitiators required, can lead to unpleasant odors. This must be avoided by disposing of the exhaust air. The acrylates are also allergenic, something for them Employees at the POS require special training and appropriate protective equipment for maintenance, cleaning or troubleshooting. The disposal of faulty batches / rejects is also not without problems for the employees. In addition, quality testing is difficult for people who are inexperienced in UV coating technology. The use of UV lacquers is more suitable for industrial companies and less for employees in hardware stores, in the timber trade, in flooring specialist stores, etc. In addition, a variation in the structure of the surface is hardly possible, so that only one surface is available.

A similar procedure is used in the EP 3 067 219 A1 described. The same disadvantages apply here as for the above-mentioned document. In addition, the coating with a synthetic resin as a wear layer with the aid of pressure and temperature is described there. For reasons similar to painting (high technical effort, high technical know-how, disposal problems, etc.), this is to be classified as impractical. In addition, the coating with synthetic resins takes place at relatively high temperatures (approx. 200 ° C), which means that such a system requires a considerable amount of energy.

The resulting disadvantages are odor nuisance, no surface variations, sophisticated technology, so that employees with a great technical understanding are required, exhaust air and disposal problems.

The present invention is therefore based on the technical problem of providing a device that enables the end customer to purchase a floor he designed himself at the point of sale (POS), such as a building supplies store, which he can take away immediately. It is possible to work either with your own or with existing decors (in digital form). For the employees at the point of sale, the operation and maintenance of the system used to manufacture the floor should be as simple and safe as possible. There should be no emissions or unpleasant odors. In addition, the rectification of problems, maintenance and replacement of the system should be as easy as possible.

This technical object is achieved by a method with the features of claim 1 and a device with the features of claim 12.

• Bereitstellen von mindestens einem formatierten Laminatpaneelrohling durch eine Partei A, insbesondere einen Laminathersteller, wobei der Laminatpaneelrohling eine mit einer Beschichtung als Druckgrundierung und mindestens einem Gegenzug verpresste Trägerplatte und in die Paneelkanten eingefügte Verbindungselemente umfasst,
• Aufdrucken von mindestens einem individuell durch den Endverbraucher ausgewählten Dekor auf den Laminatpaneelrohling im Digitaldruck;
• Aufpressen von mindestens einer thermoplastischen Folie als Verschleißschicht auf das Druckdekor.

Accordingly, a method for providing laminate panels provided with individualized decorations, in particular wood-based laminate panels, for party B, in particular an end user, is provided, which comprises the following steps:

• Provision of at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, the laminate panel blank comprising a carrier plate pressed with a coating as a pressure primer and at least one counter-tension and connecting elements inserted into the panel edges,
• Printing of at least one decoration selected individually by the end user on the laminate panel blank in digital printing;
• Pressing at least one thermoplastic film onto the printed decoration as a wear layer.

Party A is to be understood as meaning, in particular, a laminate manufacturer, including a supplier, dealer or the like, who provides a party B with laminate panel blanks for individualization in the manner of an intermediate product.

Party B is to be understood in particular as an end user, including interior decorators or architects who use laminate panels as a finished end product for cladding floors, walls and / or ceilings or who offer them for use.

Accordingly, a method (and a device for carrying out this method) is provided, a non-individualized laminate panel blank being initially provided by the manufacturer. As will be described in detail further below, the manufacturer presses a large-format carrier plate with a primer layer, if necessary a primer and a counter-layer, the primer layer having a uniform, preferably light, color. The primer layer can be provided with structures. The pressed, large-format plate is divided into individual panels and provided with known locking elements on the side edges. The manufacturer thus provides laminate panel blanks with a high degree of processing, which can then be individually designed by the end user.

The manufacturer delivers the laminate panel blank to a point of sale (e.g. hardware store). Here, according to the present method, a decoration individually designed by the end user is digitally printed and this printed decoration is provided with a wear layer based on a film. The application of liquid paint or resin layers as a wear layer is therefore dispensed with, so that the finishing process can be carried out more easily and safely. The end user also has the option of integrating their own decors or inlays into the floor.

The system used for the present process at the point of sale comprises a magazine in which laminate panel blanks (coated, primed and provided with tongue and groove) are located. The laminate panel blanks are printed with a digital printer either with decors that the system supplier makes available to the end user or with decors that the end user transfers to the system via a digital file (e.g. stored on a USB stick). There is also the option of integrating inlays, names, etc. into a decor specified by the system supplier. Further editing of the decor files is also possible using simple software (rotating, mirroring, enlarging, reducing, etc.). In addition, the result of the adjustments can be assessed not only on a screen but also on a printout. A film, which is optionally provided with a layer of lacquer on the top, is then applied to the printed decoration with the aid of a heated roller.

The fact that the laminate floor blanks are delivered to the POS solves the problem of supplying end customers with small quantities that has arisen as a result of the individualization. In this way, minimal quantities (e.g. lot size 1) can be individually designed for the end user. This would not be possible with the laminate manufacturer himself. The possibility of individualization of a product by the end customer himself is the maximum possible participation of the end user in the production of the product.

Furthermore, only a digital printer and roll lamination in the width of the board are required for surface finishing. If necessary, foils for different usage classes can also be used, as this only requires an exchange of a roll.

The advantages resulting from the present process are manifold: the end product is ready immediately, modifications to the decor can be carried out, surfaces can can be varied, it is a simple process that can be carried out in a flexible system and customer-specific quantities can be provided.

As described, the laminate panel blank with the pressure primer, backing and locking elements is provided by the laminate manufacturer.

The laminate panel blank comprises a wood-based panel as the core or carrier board, which can be a medium-density fiber (MDF), high-density fiber (HDF) or chipboard or coarse chipboard (OSB) or plywood board and / or a wood-plastic board.

In one embodiment, an unsanded wood fiber board, in particular MDF or HDF, is used as a carrier board for the laminate panel blank, which is also provided with a pressed skin (rotting layer) on the top and has been treated with an aqueous melamine resin on the top to fill the pressed skin .

The dimensions or dimensions of the laminate panel blank correspond to the formats that are typically available in retail (e.g. hardware stores). The laminate panel blank can have dimensions of 1395 × 195 mm with a thickness between 4 to 15 mm, preferably 6 to 12 mm. However, other formats would also be possible.

As stated above, the at least one laminate panel blank has a coating as a printing primer. This primer is applied to large-format carrier plates by the manufacturer. In order to ensure particularly good printability of the laminate panel blanks produced in this way, the primer is in particular colored. In particular, several colors are possible here, such as white, beige, yellow or brown.

In one embodiment, the at least one printing primer consists of a liquid coating made of a resin, preferably of a formaldehyde resin, such as melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin. After intermediate drying, a pigmented layer is applied to this primer, for example with a binder based on casein or soy protein. White pigments such as titanium dioxide (TiO ₂ ) can be used as color pigments. Further color pigments can be calcium carbonate, barium sulfate or barium carbonate. The liquid primers can be applied to the surface of the carrier plate using a roller.

It is also conceivable that the primers consist of at least one, preferably of at least two or more successively applied layers or orders, the amount applied between the layers or orders being the same or different, i.e. the amount applied for each individual layer can vary.

In another embodiment, the at least one printing primer consists of a colored paper impregnated with a resin. For example, colored papers are used as the printing base, the color of which corresponds to the lightest shade of the decor to be printed. If, as in the present case, the decor to be applied is not yet known, a white or at least very light primer is therefore advantageous. Any other color is also conceivable as a primer.

In a further embodiment, the large-format panel provided with the at least one pressure primer is pressed with a counter-tension. At the panel manufacturer, this is usually done in a short-cycle press. A structure can be introduced into the printing primer during the pressing process.

It is also possible for at least one primer layer to be applied to the at least one printing primer (at the panel manufacturer). Isocyanate-based compounds can be used as primers, non-aromatic, aliphatic isocyanates, such as hexamethylene diisocyanate, isophorone diisocyanate, or prepolymers which contain these isocyanates being particularly preferred. Silane-based primers can also be used, such as products from Inomat GmbH. These contain acidolysis products from silanes, e.g. from bis (3-trimethoxysilylpropyl) amine and p-toluenesulfonic acid.

The amount of the applied liquid primer is in the present case between 1 and 30 g / m ² , preferably between 5 and 20 g / m ² , particularly preferably between 10 and 15 g / m ² .

A separating film can be provided to protect the printed decoration and the primer against soiling and against sticking of the laminate floor blanks during transport and storage to the POS. For example, films with a silicone coating can be used as separating films.

The steps described for priming and, if necessary, applying a primer layer and pressing are carried out in large format at the manufacturer. The primed large format will then divided or formatted into the desired number of laminate panel blanks also at the manufacturer.

The now formatted laminate panel blanks are provided by the manufacturer with a lockable tongue and groove connection on at least two opposing edges of the panel. This enables quick and easy floating installation of the panels. Such tongue and groove connections are, inter alia, from EP 1 084 317 B1 famous.

The laminate panel blank provided by the manufacturer accordingly comprises a wood-based panel as a carrier plate with at least one pressure primer, if necessary a primer layer provided on the pressure primer, a counter-tension opposite the pressure primer and lockable tongue-and-groove connections provided on at least two opposing edges of the panel.

The laminate panel blanks are stored in a central warehouse at the laminate manufacturer. In particular, they can be cleaned and packaged beforehand in such a way that they can be printed or processed directly in the processing plant without the panels having to be cleaned again there. It now only has to be kept for a single type of panel, so that space-intensive storage of panels with different decors, different surface structures or different surfaces is no longer necessary.

The laminate panel blanks are then transported to a processing company for customization. This can be, for example, a franchise company associated with the laminate manufacturer, a hardware store, an interior designer, dealer or flooring company.

In this case, the laminate panel blanks are unpacked from the transport-safe packaging. Then - as described above - a decorative layer with a decor according to the customer's immediate requirements is applied to the primer or the primer and covered by at least one wearing layer.

As stated above, the at least one decoration (selected individually by the end user) is applied to the laminate panel blank by means of a digital printing process. In digital printing, the print image is transferred directly from a computer to a printing machine, such as a laser printer or inkjet printer. The Use of a static printing form. The decor is printed according to the inkjet principle in a single pass, in which the entire width of the upper side to be printed is spanned, with the panels being moved under the printer. However, it is also possible for the panel to be printed to be stopped under the printer and the printer to run over the surface at least once during printing.

The digital printing process enables a decor selection that corresponds to the customer's wishes, since the decor can be provided in the form of individualized computer data / software. The laminate panel blanks are printed with a digital printer either with decors provided by the system supplier or with decors that the end user transfers to the system via a file. There is also the option of integrating inlays, names, etc. into a decor specified by the system supplier. Further editing of the decor files is also possible using simple software (rotating, mirroring, enlarging, reducing, etc.). In addition, the result of the adjustments can be assessed not only on a screen but also on a printout.

In the printing step, the laminate panel blank runs through a digital printer. This makes it possible, in particular, to print different decors quickly and easily one after the other on different panels without having to convert the printing unit to a new decor in each case. Because only individual panels have to be printed and not, as is common in the prior art, entire large-format wood-based panels, the printing unit can be made small and compact and thus space-saving and inexpensive.

The printing inks are combined in separate rows of print heads in the digital printer, it being possible for one or two rows of print heads to be provided for each color. The colors of the digital printing inks are, for example, black, blue, red, reddish yellow, greenish yellow, CMYK can also be used as an option. The digital printing inks are optionally based on the same pigments that are used for analog and / or digital printing with water-based inks. The digital printing inks are preferably based on UV inks. However, it is also possible to use water-based digital printing inks or so-called hybrid inks. After printing, the decorative print is dried and / or irradiated.

The printing inks are applied in an amount between 1 and 30 g / m ² , preferably between 3 and 20 g / m ² , particularly preferably between 3 and 10 g / m ² .

As mentioned above, a thermoplastic film is applied to the printed decoration as a wear layer. In one embodiment, a transparent cover film made of a thermoplastic material, in particular made of thermoplastic polyurethane (TPU), polyethylene terephthalate (PET) or polypropylene (PP), is used. The TPU's are aliphatic systems, as they are less sensitive to yellowing.

The foils used have a thickness between 0.1 and 1 mm, preferably between 0.2 and 0.8 mm. They can have one or more layers and contain mineral components to improve wear resistance (e.g. corundum particles).

The transparent thermoplastic film is produced separately and supplied online from a roll. The at least one thermoplastic film is applied to the printed laminate panel blank at a temperature which is up to 20 ° C. above the softening temperature of the thermoplastic material of the film. By heating the film above the softening point, good adhesion of the film to the printing layer is achieved.

The film is pressed on with a line pressure between 100 and 170 N / mm, preferably 150 N / mm (an idealized line in a laminating system is assumed here).

The film is in particular laminated or calendered. The calendering is preferably carried out with a structure roll exposed to temperature. For the purposes of the present application, the term “calendering” is to be understood as meaning the application of a thermoplastic film to a carrier plate using heated rollers. This causes the surface of the thermoplastic film to melt, which after curing is connected to the surface of the carrier plate or is welded to the carrier plate and thereby adheres to the carrier plate. Accordingly, no gluing is necessary.

In a further embodiment, the at least one thermoplastic film is provided or coated with at least one lacquer layer. In this case, the thermoplastic film is provided together with the lacquer layer; ie the lacquer layer is already cured on the film, so that it is not necessary to apply and harden the lacquer layer at the POS. The at least one lacquer layer is used to Improvement of the scratch resistance and the adjustment of the degree of gloss can be applied. The lacquer layer can contain nanoparticles, for example made of silica.

The lacquer layer can consist of at least one polyurethane or of radiation-curable acrylate-containing lacquers. The radiation-curable paints used typically contain (meth) acrylates, such as polyester (meth) acrylates, polyether (meth) acrylates, epoxy (meth) acrylates or urethane (meth) acrylates. It is also conceivable that the acrylate used or the acrylate-containing lacquer is present in substituted or unsubstituted monomers, oligomers and / or polymers, in particular in the form of acrylic acid, acrylic ether and / or acrylic acid ester monomers, oligomers or polymers. The presence, as defined, of a double bond or unsaturated group in the acrylate molecule is important for the present process. The polyacrylates can also continue to be functionalized. Suitable functional groups include hydroxyl, amino, epoxy and / or carboxyl groups. The acrylates mentioned enable crosslinking or curing in the presence of UV or electron beams (EBC).

The lacquer layer is applied to the thermoplastic film in an amount between 30 and 100 g / m ² , preferably between 60 and 80 g / m ^2.

It is also possible for the at least one thermoplastic film and the lacquer layer optionally provided thereon to be provided with a structure. For this purpose, the heated roller for pressing on the thermoplastic film can have a structure. A change system can also be used to automatically change rollers so that structures can also be varied.

It is also possible for the structure in the register to run parallel to the decor, so-called EIR structure or decor-synchronous structure. For this purpose, the position and speed between the carrier plate to be structured and the structure generator (roller) are synchronized.

With the present method, a laminate panel, in particular a wood-based laminate panel, can be produced, which has a layer structure of at least one counter-sheet, a carrier plate, at least one decorative primer, optionally at least one primer layer, at least one (individualized) printed decorative layer, at least one thermoplastic film and optionally at least one lacquer layer having.

• mindestens einen Digitaldrucker zum Aufdrucken von mindestens einem Dekor auf einen Laminatpaneelrohling, welcher eine mit einer Beschichtung als Druckgrundierung und mindestens einem Gegenzug verpresste Trägerplatte und in die Paneelkanten eingefügte Verbindungselemente umfasst, im Digitaldruck; und
• mindestens einer Walzenvorrichtung zum Aufpressen von mindestens einer thermoplastischen Folie als Verschleißschicht auf das Druckdekor.

The device used to provide this laminate panel comprises

• at least one digital printer for printing at least one decor on a laminate panel blank, which comprises a carrier plate pressed with a coating as a printing primer and at least one counter-tension and connecting elements inserted into the panel edges, in digital printing; and
• at least one roller device for pressing at least one thermoplastic film as a wear layer onto the printed decoration.

The device also comprises at least one magazine in which laminate panel blanks (coated, primed and provided with tongue and groove) are located.

In a further embodiment, a cleaning device can be arranged upstream of the printing unit or digital printer.

The at least one digital printer is connected to at least one electronic data processing device. The data processing device of the digital printer comprises an 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, and an electrical control which is set up to read the selected decoration from the data memory and thus to control the printing unit that the selected decor will be printed.

The device also includes a display device via which the available decors or decors provided by the end user are displayed.

It is also possible that the at least one roller device comprises at least one roller with a structured roller. A change system can also be used to automatically change rollers so that structures can also be varied.

An essential advantage of the present device is that the at least one digital printer and the at least one roller device are adapted to the dimensions of the laminate panel blank, ie digital printer and roller device are adapted to the board width and are therefore more space-saving and cost-effective.

Specifically, the present method can be carried out in a variant, for example, in a hardware store as follows. A customer who needs laminate panels for a certain room size first receives information about the number of panels he needs. On a display device of a device with which the laminate panel blank can be finished as described above, he can view various decors that are available for selection. These decorations are stored in the form of electronic data in a data memory within the device. Alternatively, the customer or end user can bring their own decoration on a suitable data carrier (e.g. on a CD, DVD or USB stick). In this way it is possible for the customer to print an individual decor 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 laminate panel blanks are to be printed with the selected decor. Inside the device, the desired decoration is then applied to a pre-primed profiled panel and this is covered with a thermoplastic film as a wear layer. For the end user, it is possible at any time to reorder individual panels on the device described. As a result, the flexibility in the production of laminate panels is significantly increased and even the smallest order quantities with a wide variety of decors can be produced economically.

Figur 1

eine schematische Darstellung einer Ausführungsform des vorliegenden Verfahrens.

The present invention is explained in more detail below with reference to a figure and an exemplary embodiment. It shows:

Figure 1

a schematic representation of an embodiment of the present method.

Figure 1 shows the schematic representation of a method for finishing a laminate panel blank, as it can be carried out in a processing company, for example a franchisee connected to the laminate manufacturer, a hardware store or the like.

The laminate panel blanks 101 are delivered from the laminate manufacturer to the processing company in a transport-safe packaging. In a first method step, the laminate panel blanks 101 are removed from this transport-safe packaging and fed to a magazine.

In the in Figure 1 The illustrated embodiment of the method, the laminate panel blanks 101 are then fed to a cleaning device 102, in which the surface of the laminate panel blanks 101 is cleaned of possibly adhering dirt residues and dust and is thus prepared for printing. However, it is also conceivable that the laminate panel blanks 101 have been suitably cleaned in the laminate manufacturer's operation for later printing. These can then have been cleaned and placed in the transport-safe packaging. For example, by airtight welding of the transport pack into a film, it can be ruled out that the laminate panel blanks 101 then have to be cleaned again before they are printed.

After the laminate panel blanks 101 have possibly passed through the cleaning device 102, they are aligned and spaced from one another to the desired distance. The laminate panel blanks 101 are then fed to a digital printer 103. Here the surface of the panel 101 is printed with the decorative layer to be applied. For this purpose, the digital printer 103 has three print heads. Depending on the desired decor, the digital printer 103 can also have more or fewer print heads. An electronic data processing device 104 is connected to the digital printer 103. This has an in Figure 1 Input device, not shown, by means of which the user of a device for carrying out the method can select the desired decor. For this purpose, the electronic data processing device 104 has a display device via which the available decorations, which are stored, for example, on an electronic storage medium, are displayed to the user. From this selection, the user can select the desired print decor.

In order to ensure the best possible result, the decorations in the data processing device 104 are optimized and adapted to the possible formats of the laminate panel blanks 101 to be printed.

After the upper side of the laminate panel blanks 101 has been printed with a decoration, the printed panels 101 leave the digital printer 103 and are fed to a roller device 105 in which a transparent thermoplastic wear film is pressed on. The film is cut to size after the pressing process. If necessary, cooling (roller cooling) can also be integrated into the process. After pressing the wear film with the printed panel, the end user has a laminate panel that is tailored to his or her individual needs Available, which can be used, for example, as a floor element or for wall or furniture cladding.

Embodiment Provision of the laminate panel blanks at the laminate manufacturer:

The large-format wood-based panels are primed. The primer can either have a dyed-through paper as a base or consist of a liquid coating with a subsequent covering with a melamine resin coating. The liquid coating can be applied by roller application or by digital printing.

In the case of an impregnation, a colored paper is subjected to a special impregnation. First, the paper is filled with resin, then the top is sharply peeled off with a knife blade and then a line of resin is applied on the underside, which is supposed to improve the adhesion to the carrier material.

The priming is usually carried out on a large format (format 2800 mm x 2070 mm with a thickness of 4 to 15 mm, preferably 6 to 12 mm).

In any case, a subsequent pressing was carried out in a short-cycle press with a counter-pull.

The laminate flooring blanks are then produced from this large format on a milling line.

A primer can be applied before or after formatting, which improves the adhesion of the film that is applied later. This primer is applied in an amount of 10 to 20 g fl / m ² . It can be primers based on isocyanates or on a silane basis (INOFLEX NI +). A release film can be provided to protect the primer from soiling and to prevent the laminate floor blanks from sticking during transport and storage

Locking profiles (connecting means and locking elements) are usually milled into the side edges of the formatted panel blanks and, if necessary, with Plastic barrier elements incorporated, then packaged, possibly temporarily stored and sent to the point of sale.

The laminate manufacturer produces a "finished" laminate in the color white and stores it in stock.

Refinement at the point of sale (e.g. hardware store):

The laminate panel blanks are unpacked and cleaned and introduced into the system consisting of digital printer and roller device.

The system includes a magazine in which there are laminate panel blanks (coated, primed and provided with tongue and groove).

At the point of sale, the laminate flooring blanks are printed with a digital printer either with decors provided by the system supplier or with decors that the end user transfers to the system via a file. There is also the option of integrating inlays, names, etc. into a decor specified by the system supplier. Further editing of the decor files is also possible using simple software (rotating, mirroring, enlarging, reducing, etc.). In addition, the result of the adjustments can be assessed not only on a screen but also on a printout.

A TPU film, which is provided with a UV lacquer layer on the upper side, is then laminated onto the print with the aid of a heated roller at a pressure of 150 N / mm and a temperature of 140.degree. The film is fed from a roll. It is cut to size after the lamination process. The blanks are transported through the lamination press by a guide, which prevents damage to the profile areas during lamination by means of appropriate equipment.

The heated roller that presses the film onto the print is structured so that the lacquer surface can be re-structured. A change system can also be used to automatically change rollers so that structures can also be varied. The temperature used to apply the film is up to approx. 20 ° C. above the softening temperature of the thermoplastic from which the film was made.

The fact that the laminate floor blanks are delivered to the POS solves the problem of supplying end customers with small quantities that has arisen as a result of the individualization. Furthermore, only a digital printer and roll lamination in the width of the board are required for surface finishing. If necessary, foils for different usage classes can also be used, as this only requires an exchange of a roll.

Claims (15)

Method for providing laminate panels provided with individualized decors, in particular wood-based laminate panels, for party B, in particular an end user, comprising the steps: - Provision of at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, the laminate panel blank comprising a carrier plate pressed with a coating as a pressure primer and at least one counter-tension and connecting elements inserted into the panel edges, - Printing of at least one decoration selected individually by Party B, in particular the end user, on the laminate panel blank in digital printing; - Pressing at least one thermoplastic film as a wear layer onto the printed decoration. Method according to Claim 1, characterized in that the at least one printing primer of the laminate panel blank consists of a resin provided with colored pigments, preferably a pigmented formaldehyde resin. Method according to Claim 1, characterized in that the at least one printing primer of the laminate panel blank is a colored paper impregnated with a resin. Method according to one of the preceding claims, characterized in that the at least one pressure primer of the laminate panel blank is provided with a structure. Method according to one of the preceding claims, characterized in that at least one primer layer is provided on the at least one pressure primer of the laminate panel blank. Method according to one of the preceding claims, characterized in that the at least one decorative print is provided in the form of individualized computer data / software. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film provided as a wear layer is a transparent cover film made of a thermoplastic material, in particular thermoplastic polyurethane (TPU), polyethylene terephthalate (PET) or polypropylene (PP). Method according to one of the preceding claims, characterized in that the at least one thermoplastic film is applied to the printed panel blank at a temperature which is up to 20 ° C above the softening temperature of the thermoplastic material of the film. Method according to one of the preceding claims, characterized in that at least one lacquer layer is provided on the at least one thermoplastic film. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film and the lacquer layer optionally provided thereon are provided with a structure. Laminate panel, in particular wood-based laminate panel, producible in a method according to one of the preceding claims, characterized by a layer structure of at least one counter-sheet, a carrier plate, at least one decorative primer, optionally at least one primer layer, at least one printed decorative layer, at least one thermoplastic film and optionally at least one lacquer layer. Apparatus for providing a laminate panel provided with individualized decorations in a method according to any one of claims 1 to 10 - At least one digital printer for printing at least one decor on a laminate panel blank, which is one with a coating as Comprising printing primer and at least one backing pressed carrier plate and with connecting elements inserted into the panel edges, in digital printing; and - At least one roller device for pressing at least one thermoplastic film as a wear layer onto the printed decoration. Device according to Claim 12, characterized in that the at least one digital printer is connected to at least one electronic data processing device. Device according to one of Claims 12-13, characterized in that the at least one roller device comprises at least one roller with a structured roller. Device according to one of Claims 12-14, characterized in that the at least one digital printer and the at least one roller device are adapted to the dimensions of the laminate panel blank.

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