EP4124467B1 - Ein verfahren zur herstellung eines paneels - Google Patents

Ein verfahren zur herstellung eines paneels

Info

Publication number
EP4124467B1
EP4124467B1 EP21188714.6A EP21188714A EP4124467B1 EP 4124467 B1 EP4124467 B1 EP 4124467B1 EP 21188714 A EP21188714 A EP 21188714A EP 4124467 B1 EP4124467 B1 EP 4124467B1
Authority
EP
European Patent Office
Prior art keywords
substance
layer
additional
foil
discrete quantities
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP21188714.6A
Other languages
English (en)
French (fr)
Other versions
EP4124467A1 (de
Inventor
Bruno Vermeulen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin BV
Original Assignee
Unilin BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Unilin BV filed Critical Unilin BV
Priority to EP21188714.6A priority Critical patent/EP4124467B1/de
Publication of EP4124467A1 publication Critical patent/EP4124467A1/de
Application granted granted Critical
Publication of EP4124467B1 publication Critical patent/EP4124467B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B44C3/025—Superimposing layers to produce ornamental relief structures

Definitions

  • Known methods for manufacturing panels comprise the step of providing a top layer in the form of a sheet, normally a thermoplastic sheet or a melamine impregnated sheet.
  • Said sheet can comprise a pre-formed surface structure for providing the surface of the panel of a three-dimensional relief.
  • Such a method is known from EP 2 927 017 .
  • the curable substance forms a layer between the substrate and the air-tight foil. Due to its air-tightness the foil functions as a barrier against oxygen transfer through the foil. This means that local inert conditions at the curable substance are created.
  • the foil comprises discrete quantities of an additional substance in the form of anti-wear particles.
  • the final product contains the foil including the anti-wear particles.
  • the structure on the sheet is obtained by embossing plates or rollers that have to be previously prepared.
  • embossing technique is so expensive that is convenient only for high volume production batches and is also quite rigid and limited in the variety of the design.
  • WO 2020/115337 A1 discloses a method for obtaining a raised pattern on a substrate and to the device used, wherein the method comprises the following steps of moving a substrate having one face; supplying a film with a first face; projecting onto the first face a raised-pattern product using digital printing technology so as to generate a positive raised pattern on the first face; fixing the positive raised pattern on the film; applying an overlay product; obtaining a negative raised pattern on the overlay product by contact with the positive raised pattern; and fixing the negative raised pattern on the face of the substrate.
  • EP 3 892 388 A1 which is a European prior right under Article 54(3) EPC and thus only relevant for novelty and not inventive step, discloses a method for producing a structured surface of a plate-shaped material, in which a lacquer layer is applied to the surface of the plate-shaped material, in which a film that is at least partially permeable to radiation is placed on the lacquer layer, in which before or after the film is placed a structured absorber layer is applied to the film using an absorber material that is at least partially impermeable to radiation, in which radiation is subsequently applied to the lacquer layer through the film in a first curing step, the lacquer layer being cured at least in sections and at least partially depending on the permeability of the structured absorber layer of the film, in which the film is lifted off the lacquer layer and in which the lacquer layer is cured, preferably completely, by means of radiation in a second curing step.
  • An object of the invention is to provide an improved method of manufacturing a panel for covering a floor, a wall, a ceiling or furniture.
  • This object is accomplished by the invention with a method comprising the steps of supplying a substrate, applying a layer of curable substance onto the substrate, applying a substantially air-tight foil onto the layer of curable substance such that the layer of curable substance is sandwiched between the substrate and the foil, subsequently curing at least a part of the layer of curable substance by means of radiation through the foil resulting in a layer of at least partly cured substance, wherein the method comprises a step of applying discrete quantities of an additional substance at a side of the curable substance which is directed away from the substrate and in that after the step of curing the foil and the discrete quantities of an additional substance are removed from the layer of at least partly cured substance so as to form the panel.
  • the presence of the discrete quantities of an additional substance at a side of the curable substance where the air-tight foil is located before the step of curing advantageously provides the opportunity to create a surprising three-dimensional surface structure at the layer of curable substance, which three-dimensional surface structure is exposed after removing the foil and the discrete quantities of an additional substance. Due to creating inert conditions during the step of curing the layer of at least partly cured substance becomes a strong coating.
  • the strong coating may have such characteristics that anti-wear particles as applied in the above-mentioned prior art may be omitted.
  • the curable substance may comprise a synthetic resin which is polymerized during the radiation treatment, more specifically via free radical polymerization. Radiation generates radicals in the curable substance. Since the chemical affinity between a radical and oxygen is higher than the affinity of the radicals with each other inert conditions are advantageous.
  • the radiation is UV radiation.
  • the curable substance may contain photo initiators for initiating free radical polymerization. In particular, mercury-free UV LEDs appear to be appropriate because of their advantageous penetration characteristics into the curable substance.
  • the curable substance may be applied by means of inkjet printing, screen printing, roller printing, spraying, curtain coating or the like.
  • the curable substance is applied by means of coating techniques, preferably roller coating, in order to apply higher quantities of curable substance than those applicable through printing technique.
  • coating techniques preferably roller coating
  • the curable substance may be a liquid, or a pasty substance.
  • the curable substance after curing, may the uppermost of layer of the panel and has to exert good surface performances.
  • said curable substance forms a layer having a thickness of at least 100 ⁇ m, more preferably at least 300 ⁇ m.
  • said curable substance may form a layer having a thickness comprised between 100 and 1500 ⁇ m, more preferably between 300 and 1000 ⁇ m.
  • To thicker layer correspond a generally higher abrasion resistance.
  • a thicker layer it may be possible to obtain a deeper and more realistic relief.
  • the characteristics of the air-tight foil correspond to the type of radiation that is used.
  • the foil may be transparent, wherein transparent means that it is transparent for the radiation used for curing, for example in case of UV curing it is transparent for UV radiation, but may be opaque for visible light. Since the foil is removed after the step of curing the colour of the foil is of less relevance for the esthetical properties of the final product.
  • the foil may be made of thermoplastic material, for example PVC.
  • the discrete quantities of an additional substance may be solid particles or the additional substance may be a liquid or a pasty substance, for example droplets.
  • the liquid or the pasty substance may be solidified afterwards, for example via curing, preferably together with curing the curable substance. Since they are removed from the layer of at least partly cured substance the discrete quantities of an additional substance do not need to have anti-wear properties.
  • the discrete quantities of an additional substance may also be called placeholders, which remain at the same location with respect to the layer of curable substance during the step of curing.
  • the substrate may be rigid or flexible such that the resulting panel is rigid or flexible, respectively. It may be made of wood-based material like MDF, HDF, or thermoplastic, preferably vinyl, for example WPC, SPC or LVT, metal, glass, stone, ceramic, textile, non-woven fabric, polymeric composite, mineral-based material like MgO, or the like. Furthermore, although less preferred, the substrate may be a flexible thin sheet such that the resulting product itself can be an intermediate product that can be attached to a second substrate.
  • the resulting panel may be suitable for a floor, wall or ceiling covering or alternative coverings.
  • the product may also be a panel that is suitable for furniture, or the like.
  • the step of applying the discrete quantities of an additional substance may comprise a digital printing technique, for example inkjet printing. This provides the opportunity to print the discrete quantities of an additional substance in numerous different possible patterns and to control the penetration depth of the discrete quantities of an additional substance into the layer of curable substance.
  • the discrete quantities of an additional substance are applied onto the foil after applying the foil onto the layer of curable substance, wherein the discrete quantities of an additional substance allow less transmission of the radiation than the foil.
  • the discrete quantities of an additional substance do not penetrate into the layer of curable substance, but portions of the layer of curable substance located directly below the respective discrete quantities of an additional substance remain uncured or become partly cured. This provides the opportunity to treat these portions separately after removing the foil and the discrete quantities of an additional substance from the layer of at least partly cured substance in order to create a different appearance at these portions.
  • the curable substance can be transparent or translucent, in particular after the curing step.
  • the transparency of the curable substance is preferably refereed to the visible radiation so that the curable substance may be visibly transparent and the decorative layer is visible through the curable substance.
  • Preferred diacrylates are 1,6-hexanediol diacrylate, dipropyleneglycol diacrylate, acrylic acid 2-(2-vinyloxy-ethoxy)-ethyl ester, propoxylated neopentylglycol diacrylate, isobornyl acrylate, mono-2acrryloyloxyethyl phtalate, tricyclodecane dimethanol diacrylate, 2-carboxyethyl acrylate, Benzyl acrylate, tripropylene glycol diacrylate and 1,4-butanediol diacrylate.
  • Preferred triacrylates are trimethylolpropane triacrylate and pentaerythritol triacrylate.
  • suitable polyfunctional prepolymers are also epoxyacrylate and silicone-acrylate oligomers, which are preferably used together with the diacrylates or triacrylates mentioned in the mixture which can be copolymerized by a free radical mechanism.
  • Fig. 1 is an illustrative view, illustrating an alternative method not according to the invention, but illustrative of features of the invention.
  • the layer of cured substance 3' is fully cured at the UV radiator 8, which may be achieved by using relatively small particles or particles which allow transmission of UV radiation. It is also conceivable that the upper surface of the layer of curable substance 3 is not fully cured at portions directly below the particles. These portions may be cured in an additional radiation curing step.

Landscapes

  • Application Of Or Painting With Fluid Materials (AREA)
  • Laminated Bodies (AREA)

Claims (6)

  1. Verfahren zur Herstellung eines Paneels, das die folgenden Schritte umfasst: das Bereitstellen eines Substrats (1); das Aufbringen eines Dekormusters auf eine obere Oberfläche des Substrats (1) mittels Tintenstrahldruck; das Aufbringen einer aus einer aushärtbaren Substanz (3) bestehenden Schicht auf das Substrat (1); das Aufbringen einer im Wesentlichen luftdichten Folie (6) derart auf die aus einer aushärtbaren Substanz (3) bestehende Schicht, dass die aus einer aushärtbaren Substanz (3) bestehende Schicht zwischen dem Substrat (1) und der Folie (6) liegt; das nachträgliche Aushärten mindestens eines Teils der aus einer aushärtbaren Substanz (3) bestehenden Schicht mittels einer durch die Folie (6) hindurchtretenden Strahlung, wodurch eine aus einer mindestens teilweise ausgehärteten Substanz (3', 3") bestehende Schicht erzielt wird; wobei das Verfahren einen Schritt umfasst, wobei diskrete Mengen einer zusätzlichen Substanz (5) auf eine Seite der aushärtbaren Substanz (3) aufgebracht werden, deren Ausrichtung von dem Substrat (1) weg zeigt; und wobei nach dem Schritt, wobei die Folie (6) ausgehärtet wird (8), die diskreten Mengen einer zusätzlichen Substanz (5) von der aus einer zumindest teilweise ausgehärteten Substanz (3', 3") bestehenden Schicht entfernt werden, um das Paneel zu erzielen; wobei die diskreten Mengen einer zusätzlichen Substanz (5) auf die Folie (6) aufgebracht werden, dadurch gekennzeichnet, dass die diskreten Mengen einer zusätzlichen Substanz (5) auf die Folie (6) aufgebracht werden, nachdem die Folie (6) auf die aus einer aushärtbaren Substanz (3) bestehende Schicht aufgebracht wurde; und wobei die diskreten Mengen einer zusätzlichen Substanz (5) eine Durchlässigkeit der Strahlung erzielen, die geringer ist als die der Folie (6); dass die aus einer aushärtbaren Substanz (3) bestehende Schicht während des Aushärtungsschritts (8) teilweise ausgehärtet wird; wobei nach dem Schritt, wobei die Folie (6) und die diskreten Mengen einer zusätzlichen Substanz (5) entfernt werden, die aus einer teilweise ausgehärteten Substanz (3") bestehende Schicht durch einen Schritt verarbeitet wird, wobei ein zusätzliches Aushärten durch Bestrahlung (10) erfolgt; und dass der Schritt, wobei ein zusätzliches Aushärten durch Bestrahlung durchgeführt wird, eine Bestrahlung mittels einer Excimerlampe (10) umfasst.
  2. Verfahren nach Anspruch 1, wobei die diskreten Mengen einer zusätzlichen Substanz (5) mittels eines digitalen Drucks (4) aufgebracht werden.
  3. Verfahren nach einem der vorstehenden Ansprüche, wobei nach dem Aushärtungsschritt die aushärtbare Substanz (3) in Teilen (9), die unterhalb der diskreten Mengen einer zusätzlichen Substanz (5) angebracht sind, noch unausgehärtet ist; wobei die unausgehärteten Teile in dem Schritt (10) ausgehärtet werden, wobei eine zusätzliche Aushärtung erfolgt.
  4. Verfahren nach Anspruch 3, wobei die unausgehärteten Teile (9) nur obere Teile der aus einer teilweise ausgehärteten Substanz (3) bestehenden Schicht an einer ihrer von dem Substrat (1) abgewandten Oberflächen darstellen; wobei die Tiefen der oberen Teile in der aus einer teilweise ausgehärteten Substanz (3") bestehenden Schicht weniger als die Hälfte ihrer Dicke betragen.
  5. Verfahren nach einem der vorstehenden Ansprüche, wobei die diskreten Mengen einer zusätzlichen Substanz (5) in einem Muster aufgebracht werden, das mit dem Dekormuster registriert ist.
  6. Verfahren nach einem der vorstehenden Ansprüche, wobei die diskreten Mengen einer zusätzlichen Substanz (5) feste Partikel (5) darstellen oder die zusätzliche Substanz eine flüssige oder pastöse Substanz darstellt.
EP21188714.6A 2021-07-30 2021-07-30 Ein verfahren zur herstellung eines paneels Active EP4124467B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP21188714.6A EP4124467B1 (de) 2021-07-30 2021-07-30 Ein verfahren zur herstellung eines paneels

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP21188714.6A EP4124467B1 (de) 2021-07-30 2021-07-30 Ein verfahren zur herstellung eines paneels

Publications (2)

Publication Number Publication Date
EP4124467A1 EP4124467A1 (de) 2023-02-01
EP4124467B1 true EP4124467B1 (de) 2025-10-01

Family

ID=77431100

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21188714.6A Active EP4124467B1 (de) 2021-07-30 2021-07-30 Ein verfahren zur herstellung eines paneels

Country Status (1)

Country Link
EP (1) EP4124467B1 (de)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
PL3831615T3 (pl) * 2008-12-19 2025-04-07 Unilin, Bv Panel powlekany z materiału syntetycznego możliwego do spieniania lub spienionego
PL2927017T5 (pl) 2014-04-04 2022-06-20 Flooring Industries Limited, Sarl Sposób pokrywania substratu
EP3403847B1 (de) * 2017-05-17 2019-10-02 SURTECO GmbH Verfahren zur herstellung einer mehrschichtigen materialbahn mit dekorsynchron strukturierter oberfläche sowie die verwendung derselben
US12128603B2 (en) * 2018-12-03 2024-10-29 Jesus Francisco Barberan Latorre Method and device for obtaining a raised pattern on a substrate
EP3892388B1 (de) * 2020-04-06 2023-06-07 Fritz Egger GmbH & Co. OG Verfahren und vorrichtung zur herstellung einer strukturierten oberfläche eines plattenförmigen materials

Also Published As

Publication number Publication date
EP4124467A1 (de) 2023-02-01

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