EP4188619A1 - Procédé et appareil pour la production d'une structure de surface tridimensionnelle - Google Patents

Procédé et appareil pour la production d'une structure de surface tridimensionnelle

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Publication number
EP4188619A1
EP4188619A1 EP21721620.9A EP21721620A EP4188619A1 EP 4188619 A1 EP4188619 A1 EP 4188619A1 EP 21721620 A EP21721620 A EP 21721620A EP 4188619 A1 EP4188619 A1 EP 4188619A1
Authority
EP
European Patent Office
Prior art keywords
resin
liquid
image
digital model
digital
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.)
Pending
Application number
EP21721620.9A
Other languages
German (de)
English (en)
Inventor
Giorgio Macor
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of EP4188619A1 publication Critical patent/EP4188619A1/fr
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • 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
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065—After-treatment
    • B05D3/067—Curing or cross-linking the coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B05D7/542—No clear coat specified the two layers being cured or baked together
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Definitions

  • the present invention relates to a method and an apparatus for producing a surface structure.
  • the invention relates to a method for producing a three-dimensional structure on a substrate by means of digital printing.
  • the present invention is part of the technical field of materials and methods for generating three-dimensionality and embossing on the surfaces of manufactured articles, substrates, supports in different types of materials such as for example panels for producing floors, coverings, furnishings and more generally for surfaces of architecture and design.
  • the technology subject of the present invention can also be used to reproduce microstructures that can be used in the biological, optical, and electronic fields.
  • the present invention exploits the combination of both the properties of traditional technologies, which offer high mechanical, chemical-physical properties and low costs, and the versatility of digital technologies which allow total customization and high precision.
  • Digital printing and in particular inkjet printing is increasingly establishing itself in industrial sectors, replacing traditional methods based on analogue printing.
  • the advantages of digital printing are considerable and include high flexibility, the ability to produce short runs and the reduction of consumable waste.
  • the materials can consist of wood and derivatives (MDF/HDF/Particleboard/plywood), plastics (PVC/polyolefins), metals, on which the image is printed and which in turn is normally protected by a paint in order to increase its resistance to abrasion and scratches.
  • MDF/HDF/Particleboard/plywood plastics
  • PVC/polyolefins plastics
  • metals on which the image is printed and which in turn is normally protected by a paint in order to increase its resistance to abrasion and scratches.
  • the finishing after printing involves the use of a layer of melamine resin (laminates) or a paint applied with the normal techniques in use (roller/spray/veil/die).
  • the varnish can be of various kinds, photo cross-linkable, epoxy, polyurethane, hot-melt and can contain water and/or solvents to control its viscosity.
  • Embossing is normally performed on the surface layer and can be obtained with various methods, traditionally by pressing with molds, rollers, or tapes on which the structure to be imprinted is reproduced.
  • the process can take place by pressure on resins that are not totally hardened, on thermoplastic materials, on photoreticulable resins with simultaneous irradiation and photopolymerization.
  • a desired feature is to have the embossed structure in register with the printed image or to obtain a correspondence between concavity/convexity and the printed image.
  • register embossing better known with the English acronym EIR: Embossing In Registration
  • EIR Embossing In Registration
  • the modern scanners used to acquire the image of materials for example METIS DRS 2000, also allow the simultaneous acquisition of the surface structure which can be advantageously used for embossing in register with the image.
  • Patent EP 3 109 056 A1 provides for the use of a UV formulation applied by ink jet printing on an uncured UV varnish to generate three-dimensional structures in order to imitate the wood grain.
  • Patent EP 2 555878 B1 describes a method for making periodic structures.
  • Patent US20100092688A1 describes a method for forming structures on an organic film by localized application of an immiscible liquid.
  • the technologies described above while providing a three-dimensional structure using digital technology, suffer from the limitations related to the control of the obtainable structure and related to the fact of requiring paints developed appropriately to maximize the 3D effect. In particular, they are limited when the paint to be embossed contains anti-abrasive fillers such as aluminum oxide (corundum). Furthermore, the aforementioned technologies can be used with photo-cross linkable paints while they are difficult to apply to other types of paints.
  • the Applicant has found a method for making a three-dimensional structure on a substrate using digital printing technology.
  • the method of the invention advantageously provides for the application, by digital printing, of a liquid B on a resin A and/or ink and/or paint that contain said resin A when the resin A has not yet solidified or is partially solidified.
  • Liquid B consists of or contains substances capable of polymerizing and/or solidifying the mixture of resin A with liquid B.
  • the resin A and the mixture AB are then solidified and/or polymerized even at different times.
  • the polymerized or uncured resin A is removed from the polymerized mixture AB, generating a three-dimensional structure .
  • the method of the invention exploits the different hardness of the applied materials for then removing the more fragile one, leaving the more tenacious material unchanged, this means the material being mechanically and/or chemically resistant to the action of a removing tool of the mechanical and/or chemical and/or physical kind.
  • the invention therefore relates to a method for generating a three-dimensional surface including the steps of:
  • the method of the invention faithfully reproduces a structure in register with the corresponding image in an efficient and economical way.
  • the method of the invention uses digital printing technology to emboss the substrate.
  • the method of the invention is flexible and capable of managing single files.
  • the embossed structure obtained with the method object of the invention has the desired resistance and hardness characteristics since the same protective paint used for the protection of the substrate is embossed, as in the case of panels used for flooring or for furniture or furnishings for furniture.
  • resin A consists of the anti-scratch and anti-abrasion protective paint.
  • step A for applying the resin A on the substrate is preceded by the printing step on the substrate of an image that is uniquely correlated with the surface structure, while step B) provides for the application of liquid B according to a distribution pattern which determines the generation of a surface structure corresponding to said image, i.e. in register with said image.
  • An advantageous executive variant provides for the printing of the image and at least of the liquid B by digital printing and in particular by inkjet printing.
  • the invention provides for the generation of a digital representation of the image and of the corresponding digital structure which is used as a digital model to control the digital printing process or the distribution of the colors of the image on the surface of the substrate and the distribution of liquid B for the formation of the surface structure corresponding to the image.
  • the said digital model is made by scanning a natural sample for the acquisition of both the image that represents the surface appearance of the said digital model, and for the acquisition in register with the said aspect of the three-dimensional structure of said surface, the said image and the said three- dimensional structure being acquired in register one with the other, i.e. the correspondence of position, color and shape between the image and the three-dimensional surface structure being maintained.
  • step A before the execution of step A there is a generation step of a pictorial digital model or an image and a digital model of the three- dimensional structure which models are in register with each other.
  • a variant embodiment provides that the said step of generating the digital model comprises the scanning of the surface of one or more samples, for example natural samples by using a laser scanner.
  • the set of commands of the digital printing device is generated by processing for the application in register of the inks and subsequently of the liquid B according to a distribution that generates the image and the three-dimensional structure related to it.
  • resin A is a photocurable and/or photoreticulable resin.
  • a further step E or a step B2 is envisaged which provides for the application of a substance that modifies the opacity and/or the surface luster, which is carried out in register, according to a spatially correlated digital model and which is brought into register with the digital model of the image and/or of the digital model of the digital structure.
  • Step E identifies a step subsequent to the step of eliminating the uncured or not solidified resin A or in any case the resin which is less resistant than the mixture of resin A and resin B.
  • Step B2 means a step immediately following step B of applying liquid B on resin A.
  • the application of the opacification/gloss layer is also carried out using digital printing, in particular inkjet printing.
  • Figure 1 illustrates two schematic reproductions of steps A) - D) of the process according to the invention.
  • Figure 2 shows an embodiment of an apparatus for carrying out the method according of the invention
  • the present invention relates to a method for making a three-dimensional embossed coating on a substrate comprising the steps of:
  • the method of the invention exploits the different hardness of the applied materials to then remove the more fragile one, leaving the more tenacious material unchanged.
  • the resin A can be of various chemical nature such as, for example, but not limited to, a polyurethane system, an epoxy system, an acrylate system, an acrylic system.
  • resin A is made up of 100% solid material in order to maximize the embossable layer and neutralize the effect of liquid B due to the evaporation of any solvent and/or water.
  • resin A may contain water and/or a solvent, typically between 5% and 30%.
  • resin A is of a photoreticulable or photocurable nature, as described for example in the text "Radiation Curing: Science and Technology” (Pappas).
  • Photocurable or photoreticulable resins have in common the fact that they polymerize and harden thanks to the energy radiated by ultraviolet devices and/or by irradiation with EB (Electron Beam) and are divided into two types based on the crosslinking mechanism:
  • radicals typically from vinyl monomers and acrylate resins which are divided into several subcategories: epoxy acrylate, urethane-acrylate, polyester-acrylate, polyether- acrylate, amino-acrylate, silicon-acrylate, polyisoprene- acrylate, polybutadiene acrylate and monomers acrylates.
  • vinyl monomers we can mention N-vinyl caprolactam
  • NVC acryloyl morpholine
  • ACMO acryloyl morpholine
  • DVE-2 diethylene glycol divinyl ether
  • DVE-3 triethyleneglycoldivinylether
  • acrylate refers to both acrylate and methacrylate resins.
  • cationic resins such as epoxies, polyols and monomers such as oxetanes and vinyl ethers.
  • the Applicant has also unexpectedly found that by varying the surface tension of the liquid B and of the resin A it is possible to make the liquid B more or less penetrate into the resin A and thus modify the three-dimensional structure obtained after the removal of the polymerized mixture AB.
  • the surface tension of liquid B and resin A can be modulated both by selecting the chemical nature of their basic raw materials and by adding specific additives.
  • resins containing polar groups such as hydroxyls, amines and aromatic groups will have a higher surface tension than resins containing linear structures of the hydrocarbon type.
  • the table below shows the surface tension of the most common light-cross linkable monomers:
  • silicones such compounds are readily available on the market, for example marketed by BYK (BYK-UV) and by EVONIK (Tego Rad, Tego Wet, Tego Glide).
  • additives that increase surface tension include amines, macromers-modified polyacrylates, silicon and polyacrylates macromers-modified polyethers. Such compounds are readily available on the market for example marketed by BYK (BYK 3560, BYK 3565). Typically additives are added between 0.01 and 20%, preferably between 0.01 and 10%, preferably between 0.01 and 2%.
  • the resin A can be in the form of hot-melt, such as Henkel Technomelt .
  • resin A may consist of non-cross-linkable materials such as polyurethane, epoxy, plastisol, hot-melt systems (such as Kleiberit - Hotcoating).
  • photo-crosslinking systems allows to obtain detailed structures as they can be immediately fixed by photo-crosslinking.
  • This feature is unique to photocurable systems and is hardly found in other systems. Consequently, the use of hybrid systems between photo-cross linkable systems and those described above is interesting .
  • the resin A is commonly used to protect the surfaces of floors and furniture from wear, scratches and abrasion, and comprises one or more photocurable resins, photo initiators and can contain fillers, such as aluminum oxide (corundum) to increase its resistance to abrasion, talc to modify its rheology, silica to reduce its brilliance, calcium carbonate as a filler, pigments to impart color, additives such as leveling agents, wetting agents, sliding agents, modifiers of rheology.
  • the formulation of the photo-crosslinkable resin may contain rheology modifiers, such as thixotropic agents which have the function of better maintaining the shape of the embossing, both in terms of depth and definition .
  • the liquid B has a sufficiently high surface tension, compared to the resin A, so as to penetrate into the resin A while maintaining the shape and thus create detailed structures. If, on the other hand, the surface tension of liquid B would be too low compared to that of resin A, there would be a loss of definition, liquid B finding itself wetting the surface of resin A.
  • the liquid B is able to penetrate quickly and mix effectively with the resin A.
  • liquid B consists only of the substance capable of polymerizing resin A. In this way, after polymerization, the areas printed with liquid B and consisting of the mixture of liquid B and resin A, will be harder and/or more tough than the cured resin A.
  • liquid B can consist of photo-initiators such as: hydroxy-ketones: (1-Hydroxy-cyclohexyl-phenyl- ketone; 2-Hydroxy-2-methyl-l-phenyl-l-propanone)
  • - phenylglyoxalates Methylbenzoylformate; oxy-phenyl- acetic acid 2-[2oxo-2phenyl-acetoxy-ethoxy]-ethyl ester and oxy-phenyl-acetic 2-[2-hydroxy-ethoxy]-ethyl ester.
  • Liquid photo-initiators can be suitably mixed with solid photo-initiators to obtain different crosslinking speeds and depths.
  • Example of solid photo-initiators amino ketones: 2-Benzyl-2-(dimethylamino)-1-[4-(4- morpholinyl)phenyl]-1-butanone; 2-Methyl-l-[4- methylthio)phenyl]-2- (4-morpholinyl)-1-propanone; 2- dimethylamino-2- (4-methyl-benzyl)-1-(4-morpholin-4-yl- phenyl)-butan-l-one .
  • Acyl-phosphinoxides Phosphine oxide, phenyl bis
  • Benzyldimethylketals Alpha, alpha-dimethoxy-alpha- phenylacetophenone;
  • the photo initiator can be dispersed such as: Phosphine oxide, phenyl bis (2,4,6-trimethyl benzoyl) dispersed in water.
  • the photo initiator can be dissolved in a suitable vehicle.
  • liquid B can consist of photo-initiators such as: sodium hexafluorophosphate salt; blend of Iodonium, (4-methylphenyl)[4-(2-methylpropyl) phenyl]-, hexafluorophosphate (1-) (75%) in propylene carbonate (25%); high-molecular-weight sulfonium hexafluro phosphate; blend of mixed triarylsulphonium hexaantimonate salts (50%) in propylene carbonate (50%); blend of mixed triarylsulfonium hexafluorophosphate salts (45%) in propylene carbonate (55%); 4,4 -dimethyl-diphenyl iodonium hexafluorophosphate; Blend of 4,4 -dimethyl-diphenyl iodonium hexafluoro phosphate (50%) in Oxetane (50%); 10-b
  • sensitizers such as thioxanthones: isopropylthioxantone and 2,4-diethylthioxantone.
  • the liquid B could be constituted and/or contain an isocyanate if the resin A is constituted and/or contains a polyol. If, on the other hand, the resin A is constituted and/or contains an isocyanate, the liquid B could be constituted and/or contain a polyol.
  • the mixture AB once polymerized has a Tg (glass transition temperature) higher than resin A and consequently the areas printed with liquid B will be more difficult to remove than polymerized resin A alone.
  • liquid B contains additives that serve to modify its properties such as rheology and/or printability and/or color and may include leveling agents, oils, antioxidant light stabilizers, biocides, pigments, rheology modifiers, humectants, defoamers and their mixtures .
  • the liquid B has a higher surface tension than the resin A.
  • the surface tension of the liquid B can be modulated both by the selection of raw materials and by the use of additives, the same described above to modify resin A.
  • the addition of surface tension modifiers helps to improve the printability of liquid B, especially when using inkjet printers.
  • control of the depth of liquid B in resin A can be modulated in a different way:
  • liquid B has low viscosity and high solvent power with respect to resin A.
  • the solidifying and/or polymerizing reagent of the liquid B can be conveyed in a suitable vehicle to solubilize the active principle itself and/or to increase its diffusion within the resin A.
  • the photo,initiator could be delivered in a low viscosity monomer.
  • the following monomers are listed according to the degree of solvent power: EOEOEA> THFA> HDDA> DPGDA.
  • the reagent could be conveyed through a solvent or other product with low viscosity.
  • the substrate that can be used in the method according to the invention can be a material of different nature such as wood and derived products, for example MDF, HDF, chipboard, multilayer wood, cellulose-based materials such as paper or cardboard, metals, plastic material (PVC, polyester, polyolefins), stone, glass, ceramics and their composites.
  • MDF wood and derived products
  • HDF high density polyethylene
  • chipboard chipboard
  • multilayer wood such as paper or cardboard
  • metals plastic material (PVC, polyester, polyolefins), stone, glass, ceramics and their composites.
  • the substrate is chosen according to the application of the method of the invention, for example for the coating of furniture, floors, fixtures, profiles.
  • the substrate can have variable thickness depending on the application, for example in the case of decorative panels for furniture it is commonly between 8 and 20 mm, while for producing floors, thicknesses between 2 and 6 mm are used.
  • the method of the invention can also be used to create structures on films, usually plastic or paper, which are normally used for the coating and decoration of furniture and other furnishing surfaces.
  • the resin A which covers the substrate has a variable thickness.
  • resin A can have a thickness in the range l-500pm equivalent to 1-500 g/m 2 when the density of resin A is 1 g/ml.
  • weights in the order of 80-120 g/m 2 are used. Obviously, there is nothing to prevent larger quantities from being applied with the sole aim of obtaining deeper structures.
  • the resin A or a paint or an ink containing it, to be embossed can be applied on the substrate with digital technology, for example, as illustrated in Figure 2 at point 3, using inkjet printing or with the conventional techniques in use, such as roller/spray/veil/die/slot-die.
  • the resin A is a photo-cross-linkable printing varnish and/or a photo-cross- linkable printing ink applied by digital printing.
  • liquid B takes place on the resin A or paint or ink that contains it, not solidified, of an underlying printed image.
  • the photopolymerization by UV irradiation can be carried out with one or more Hg lamps and/or with LED lamps, as for example illustrated in Figure 2 at points 4 and 5.
  • the liquid B is applied on the wear layer (resin A) on which the finish is subsequently applied and consequently the mechanical removal of the polymerized resin A.
  • the mechanical removal of the polymerized AB mixture can therefore be carried out with the same machines used for the rustication/brushing of the wood.
  • These machines use brushes and/or pads made of more or less aggressive materials (steel, brass, nylon fibers, polyester fibers) depending on the hardness of the material to be removed and the desired degree of finish.
  • the equipment described above are for example produced by CEFLA (eg RSP4) and QUICKWOOD (eg CDI/300+LEV).
  • the removal of the polymerized resin A can also be carried out by jet of air with high pressure or by jet of water with high pressure.
  • the polymerized resin A can be removed with the use of a roller or adhesive tape.
  • the adhesive roll or tape can then be cleaned and reused again.
  • the polymerized or non-polymerized resin A can be removed with the use of a suitable solvent.
  • a finishing varnish is applied on the surface of the polymerized mixture AB in order to obtain the desired aesthetics in terms of gloss, touch and resistance to micro scratches (figure 2 point 7).
  • the resin A does not contain any photo-initiator and consequently after the polymerization of the mixture AB, the latter can be extracted from the resin A. Consequently, the resin A can be used again for the process.
  • the application of liquid B is carried out in two distinct phases and this allows for example to obtain combined effects using liquid B with different characteristics, such as surface tension.
  • the method object of the invention provides for the application of liquid B by means of an ink jet head.
  • Inkjet printing can be either in multi-pass/scanning mode where the image is generated with multiple passes of the head while the material to be printed advances or in single-pass mode, where the material to be printed passes only once under the heads that are installed at the width of the same material.
  • Single-pass printing is used for large runs (>1000 m 2 /h) while multi-pass printing, used for small and medium-sized runs (10-600 m 2 /h), is certainly the most common.
  • inkjet printing involves the use of a head to create and throw liquid droplets that will then form the image to be printed.
  • a head to create and throw liquid droplets that will then form the image to be printed.
  • details of this type of printing can be found in the book “Fundamentals of inkjet printing: the science of inkjet and droplets” (Hoath, Stephen).
  • the droplets produced may have different volumes and consequently different diameters.
  • a head capable of throwing 4 levels of gray will have the smallest drop of 6 pi while the largest will be 18 pi.
  • the method of the invention allows droplets to be thrown in grayscale mode. In this way the achievable effects are expanded with the possibility of creating different depths and surface microstructures at the same time.
  • the method object of the invention is advantageously used for the production of furniture and/or floors.
  • the preparation and finishing cycle depend on the material to be decorated and on the desired performance.
  • the process object of the invention can be carried out both on the wear layer and on the finish, preferably on the first.
  • the wear layer and the finish may have different degrees of opacity. In fact, if the wear layer has a higher degree of gloss than the finishing layer, it will obtain a shiny pore which will consequently be highlighted.
  • the method can be used for producing molds and transfer films/embossing papers.
  • the molds for melamine pressing generally consist of a metal plate which is then engraved mechanically and/or by corrosion thus generating the desired structure. The process is quite laborious and lengthy and also takes several weeks. The molds are then subject to chrome plating, an operation harmful to the environment that should be banned in the near future.
  • melamine pressing requires conditions of high temperature (160-180°C) and pressure (15— 70 bar), characteristics that often do not reconcile with the physical-chemical properties of cured inkjet formulations.
  • a suitable resin A can be chosen, capable of resisting the pressing conditions and creating the negative of the structure that will be obtained after the pressing process.
  • the method of the invention can be used to produce molds for pressing ceramic, leather and plastics.
  • the method of the invention can be used for producing engraving cylinders that have the same function as the molds but are mainly used on flexible materials.
  • the application of small drops can be used to generate micro-grooves and microwells of the size of a few microns typical of microfluidics for the production of sensors and functional devices.
  • the resin A may contain blowing agents in order to obtain high volumes of embossing but limiting the weight of the embossed layer and/or the cost.
  • blowing agents in order to obtain high volumes of embossing but limiting the weight of the embossed layer and/or the cost.
  • hollow polymeric microspheres filled with gas which at certain temperatures increase the volume for example EXPANCEL can be used.
  • the expansion phase takes place preferably before the application of liquid B.
  • the method object of the invention can also be used to generate three-dimensional structures typical of the graphic and/or decorative field.
  • the method object of the invention can be used to emboss printed surfaces in a traditional way (rotogravure/flexo/offset ).
  • Liquid B consists of a photo-initiator and resin A consists of a floor protection paint with reduced photo initiator content.
  • liquid B Afterwards, on the still liquid varnish, a liquid B has been applied by means of an inkjet printer of the single-pass type, the said liquid B consisting of:
  • the support was then immediately irradiated with a PHOSEON FIRELINE 395nm 8 W/cm 2 lamp and subsequently with a DR medium pressure Hg lamp. 160 w/cm Honle to (partially) cure resin A and the mixture AB.
  • the surface appears homogeneous and the areas printed with liquid B are visible to the naked eye.
  • a panel of SPC has been subjected to the cycle described in Table 2.
  • the printer used (BARBERAN - JETMASTER) was equipped with SEIKO heads while the printed image was obtained from a three-dimensional scan of a slice of natural oak, carried out with a scanner (METIS). The image was then loaded into the printer using the dedicated software (RIP).
  • the line speed was 18 m / min.
  • liquid B has been applied by means of a single-pass inkjet printer, said liquid B consisting of:
  • the panel was then passed through a QUICKWOOD CDI/300 brushing machine equipped with 3 groups of steel brushes with 0.3 mm diameter wire. Afterwards, 10 g/m2 of matt finish paint (6 gloss) cured with Hg lamps has been applied.
  • the three-dimensional structure is well defined and detailed, completely similar to the scanned natural material.
  • the said structure was then analyzed by analysis with a laser profilometer (3D profiler - USA), which resulted in a maximum depth of the structure of 95m.
  • Liquid B consists of a photo-initiator and resin A does not consist or does not contain any photo-initiator.
  • a 100m of a photoreticulable varnish has been applied by a manual film spreader to a melamine paper support, the said varnish consisting in:
  • a liquid B has been applied by means of an inkjet printer of the single pass type, said liquid B consisting of:
  • the support was then immediately irradiated with a PHOSEON FIRELINE 395nm 8W/cm 2 lamp and subsequently with a DR medium pressure Hg lamp. 160w/cm Honle to cure the AB mix.
  • the area printed with liquid B can be seen and the structure thus generated can be removed with tweezers.
  • the plate was printed with a single-pass inkjet printer, the liquid B consisting as follows: - 90% of photo-initiator OMNIRAD 1173
  • the plate was passed under a Hg lamp (160w/cm) at a speed of 12m/min, the paint (resin A) was hard to the touch.
  • the printed wood grain is evident on the surface.
  • the slab was then passed through a QUICKWOOD CDI/300 brushing machine equipped with 3 groups of steel brushes with 0.3 mm diameter wire.
  • the three-dimensional structure is well defined and detailed.
  • the plate with the structure was used in a compression press in which a 400x400x8mm MDF panel was loaded onto which a kraft paper impregnated with urea-formaldehyde resin was placed, on which a decorative paper impregnated with melamine-formaldehyde resin was placed and a melamine overlay was positioned above the latter. The whole was pressed for 30"at 180°C and a pressure of 20 bar.

Abstract

La présente invention concerne un nouveau procédé et un appareil pour produire une structure de surface comprenant les étapes consistant à : A) appliquer une résine A sur la surface d'un matériau; B) appliquer un liquide B sur au moins une partie de la résine A, lorsque la résine A est liquide ou partiellement solidifiée; C) polymériser et/ou solidifier le mélange constitué de résine A et de liquide B; d) éliminer la résine A.
EP21721620.9A 2020-04-22 2021-04-20 Procédé et appareil pour la production d'une structure de surface tridimensionnelle Pending EP4188619A1 (fr)

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IT102020000008449A IT202000008449A1 (it) 2020-04-22 2020-04-22 Metodo e apparato per generare una struttura superficiale.
PCT/IB2021/053255 WO2021214659A1 (fr) 2020-04-22 2021-04-20 Procédé et appareil pour la production d'une structure de surface tridimensionnelle

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US20240116307A1 (en) 2020-12-29 2024-04-11 Giorgio Macor Method providing a workpiece with a three-dimensionally textured surface coating
EP4201689A1 (fr) 2021-12-22 2023-06-28 Flooring Industries Limited, SARL Procédé de fabrication d'un panneau
EP4215382A1 (fr) * 2022-01-24 2023-07-26 Flooring Industries Limited, SARL Un procédé de fabrication d'un panneau
NL2030694B1 (en) * 2022-01-25 2023-08-04 Northann Building Solutions LLC Decorative panel, decorative covering, method and system for producing such a panel

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Publication number Priority date Publication date Assignee Title
US5292556A (en) * 1992-12-22 1994-03-08 E. I. Du Pont De Nemours And Company Method for preparing negative-working wash-off relief images
EP1661690A4 (fr) * 2003-08-27 2009-08-12 Fujifilm Corp Procede de production d'un modele tridimensionnel
FR2937181B1 (fr) 2008-10-10 2011-01-14 Commissariat Energie Atomique Structuration en surface de couches minces par ejection localisee de liquide immiscible.
JP5990868B2 (ja) 2010-04-09 2016-09-14 株式会社リコー インクジェット法による膜の作製方法及び膜
EP3616939A1 (fr) * 2013-01-11 2020-03-04 Ceraloc Innovation AB Gaufrage numérique
NO2750604T3 (fr) 2015-06-25 2018-03-03
US10850446B2 (en) * 2016-04-20 2020-12-01 Hewlett-Packard Development Company, L.P. Three-dimensional (3D) printing with epoxy mold compound
EP3840893A1 (fr) * 2018-08-22 2021-06-30 Giorgio Macor Procédé et appareil de génération d'une structure de surface

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WO2021214659A1 (fr) 2021-10-28

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