ES2694390T3 - Methods for manufacturing panels - Google Patents

Abstract

Method for manufacturing coated panels (1) of the type comprising at least one substrate (2) and an upper layer (3) with a pattern, said upper layer being disposed on said substrate (2), wherein the method for performing the upper layer (3) comprises at least two steps, namely a first step (S4), in which a layer of synthetic material (7) is arranged on the substrate (2), and a second subsequent step (S5), wherein a relief is arranged on the surface of said layer of synthetic material (7), wherein said relief comprises a pattern of recesses (13) and / or projections (14), characterized in that this pattern is determined and achieves at least partially by means of a printing technique that performs one or more impressions (6).

Description

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DESCRIPTION

Methods for manufacturing panels

This invention relates to methods for making panels, as well as to panels obtainable by such methods.

More particularly, the invention relates to methods for manufacturing panels of the type comprising at least one substrate and an upper layer with a pattern, said upper layer being disposed on this substrate. Here, this may relate, for example, to furniture panels, ceiling panels or floor panels, which consist substantially of a panel or basic substrate of MDF or HDF (medium density or high density fiber board) and a layer superior disposed on it. In particular, this relates to a method in which one or more layers of material are provided on the substrate, wherein at least one of these layers of material comprises a printed pattern. Preferably, this relates to a pattern that is obtained at least partially by means of a print made directly or indirectly on the substrate. However, the invention also applies to panels in which the pattern is made in another way, for example, by printing this pattern on a carrier sheet and arranging this carrier sheet on the substrate mentioned above, as is the case, for example, with laminated panels DPL (lamination of direct grip).

Such panels are known as such, for example, from US 1,971,067, US 3,173,804, US 3,554,827, US 3,811,915, WO 01/48333, WO 01/47724, US 2004/0026017, WO 2004. / 042168, EP 1 872 959, DE 197 25 829 C1 or DE 195 32 819 A1. From the aforementioned documents, it is also known that the layers of material mentioned above may comprise one or more primer layers, wherein these primer layers extend substantially below said imprint, and / or may comprise one or more finishing layers, which extend substantially above said pattern. Such finishing layers may comprise, for example, layers of transparent or translucent synthetic material, which form a protective layer on the subject, whether printed or not, and may comprise, for example, wear-resistant particles, such as aluminum oxide. . It is not excluded that this protective layer comprises a sheet of material, such as a sheet of paper, which is provided, for example, with a synthetic material, such as an aminoresin.

From the patent documents mentioned above, various methods are known for providing a structure to the surface of a coated panel. From WO 2004/042168 it is known to arrange recesses in the substrate itself or in a primer layer and to make an impression in the form of a pattern on this structured substrate. From WO 01/47725, US 3,811,915 and US 3,554,827, the arrangement of a varnish repellent medium on the printed pattern is known, in such a way the transparent varnish layer disposed thereon is selectively solidified. so that a structure is formed on the final panel. From WO 01/48333, on which the preamble of claim 1 is based, it is known to provide impressions, with the aid of a mold or press cylinder, in a layer of varnish disposed on the pattern. From WO 01/47724, it is known to provide a transparent varnish layer by means of an ink jet selectively on the motif and in this way a structure is achieved, in which the varnish layer thus provided covers the motif only partially and part of the reason is not protected against wear. From DE 197 25 829 C1, it is known to provide impressions, by means of a press mold or cylinder or press varnish, in a protective layer applied on the motif. In DE 197 25 829 C1, mainly protective layers, applied in liquid form, comprising a thermosetting resin, such as melamine, are used.

With respect to flexibility and / or with respect to the structures to be made, the techniques mentioned above leave much to be desired. For example, it is difficult to perform with these techniques, in a homogeneous manner, structures corresponding to the motif provided by the printing. Furthermore, according to some of the known techniques, the pattern remains partially unprotected against, for example, wear or moisture penetration.

In US 2002/0142106 A1 there is disclosed a method for decorating packaging materials, comprising depositing on an substrate an ink-based solution comprising thermally expandable particles. The deposition can be done with a suitable printing technique. In a subsequent step, the substrate is exposed to microwave radiation, in such a way that the particles expand and a relief is obtained on the surface of the packaging material.

The aim of the present invention is to offer alternative methods for the manufacture of coated panels of the aforementioned type, which, according to various preferred embodiments thereof, can be made more homogeneously and / or more economically than the methods of the state of the technique, and / or offer a remedy for one or more disadvantages of the methods of the prior art.

For this purpose, the invention relates to a method for manufacturing coated panels of the type comprising at least one substrate and an upper layer with a pattern, said upper layer being disposed on said substrate, wherein the method for making the upper layer comprises at least two steps, namely a first step, in which a layer of synthetic material is provided on the substrate, and a second subsequent step, in which a relief is provided on the surface of said layer of synthetic material, with the characteristic that said

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Emboss comprises a pattern of recesses and / or projections, wherein this pattern is determined and performed at least partially by a printing technique that performs one or more impressions. It is noted that, between the substrate and said layer of synthetic material, other layers of material may still be present, such as a layer representing at least a part of said pattern or the entire pattern.

It is clear that, according to this aspect of the invention, the relief is only obtained after the respective part of the synthetic layer has already been provided. Thus, in order to apply the synthetic layer itself, techniques which are suitable for the coating of flat substrates can be chosen, which considerably simplifies such a method and, therefore, limits the risk of forming unwanted inclusions, such as as inclusions of air, in the layer of synthetic material, or even rule out this risk.

Due to the fact that the pattern of the relief is determined, at least partially, by means of a print, a structure or relief corresponding to the pattern can be applied in a simpler, more uniform and flexible manner. For example, the same printing technique can be applied both to form the pattern and to form said one or more prints, so that a similar resolution can possibly be achieved in the pattern and in the respective part of the relief. Preferably, printing is applied by means of a digital printing technique, such as ink jet printing. Of course, it is not ruled out that printing techniques, such as offset printing or gravure printing, for example, by means of press cylinders, are applied.

It is noted that the color and / or dye of said one or more impressions, which are responsible for the respective part of the structure or relief, may possibly remain visible on the decorative side of the final coated panel. In the case of a wooden structure, in which the pores of the wood are imitated by a structure of recesses, in this way the color and / or the dye of the pores of the wood can be realized.

The method of the invention can be practiced in a variety of possible ways. Next, four possibilities for this are discussed.

According to a first possibility, use is made of an impression that is located under said layer of synthetic material and is applied, for example, in a step that is carried out before or simultaneously with said first step. For example, one can work with an impression by means of an expandable agent, which then, according to the invention, after applying the layer of synthetic material, expands during said second step and in this way deforms the layer of synthetic material arranged about it.

During expansion, the layer of synthetic material may still be soft or already complete or only partially solidified. When a layer of synthetic material is used that is not completely solidified, it can also solidify at the same time when the structure is formed.

The expansion of the printing can be initiated, for example, by supplying heat by means of an oven or radiation. In this case, the expansion may possibly be restricted by a mechanical molding element, which is brought into contact with the layer of synthetic material, in such a way that better defined structures can be achieved, which, among others, show smaller rounded parts and / or smaller The use of such a molding element can be interesting, for example, to form bevels on one or more edges of the panels in question.

Instead of printing with an expandable agent, according to said first possibility, printing can also be performed with an agent that prevents expansion, wherein this agent locally counteracts a globally desired expansion. Such an embodiment is of interest when a flat overall structure has to be formed, which must show recesses only on a limited surface. This may be the case, for example, when a wooden structure is imitated, in which the pores of the wood are present as recesses on a globally flat surface. Another example of this is the formation of joints or bevels.

Specifically, for example, as an agent preventing expansion, an agent comprising benzotriazole and / or tolyltriazole can be applied, for example. Such a product is capable of decreasing or preventing the expansion of a synthetic material, such as PVC. As an expanding agent, an agent which, as such, comprises PVC can be applied.

According to an auxiliary possibility of said first possibility, said impressions that determine the structure are not only located below said layer of synthetic material, but also below said reason. According to this possibility, the motive itself obtains a structure and depth effects can be achieved.

According to another additional possibility of said first possibility, the expansion agent or that prevents the expansion is located in the reason and / or forms part of this reason. For example, such an agent can be applied to perform those parts of a pattern that are intended to be present as a projection, respectively recessed in the surface of the coated panel. Thus, the nerves of the wood and / or the pores of the wood of a wood pattern can be printed by means of a dye or ink comprising an agent that prevents expansion.

According to a second possibility, use is made of an impression that is located on top of said layer of synthetic material and is provided, for example, in a step following said first step. Such an impression can be made, for example, with an agent which, before or after its activation, is capable of forming recesses on the surface of

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said layer of synthetic material. For example, an agent can be chosen which, possibly after its activation, can dissolve, erode, burn, melt or soften the plastic layer locally, so that recesses can be formed at the location of the impression. the layer of synthetic material, possibly after rinsing or otherwise removing the affected part of the synthetic layer.

According to another example of this second possibility, such an impression can be made with an agent which, before or after its activation, is capable of forming projections on the surface of said layer of synthetic material. This can be done, for example, because the printing as such already has a certain thickness and adheres to the layer of synthetic material, or because the printing comprises an agent that locally causes the synthetic material to expand or that can prevent such expansion . Here, this can be done in a manner similar to that of said first possibility, however, with the difference that the respective expandable or impeding expansion agent is now located on the layer of synthetic material.

According to a third possibility of the invention, said printing is applied to form a structure in a transfer element or press element, such as a roller, wherein the transfer element thus structured at least partially is applied to form recesses in said synthetic material layer. Preferably, said structure in the transfer element is formed at the same time and / or in line with the formation of the recesses in the layer of synthetic material. Preferably, it is the printed agent itself that forms the structure of the transfer element. For this purpose, for example, a wax or varnish can be applied; furthermore, agents comprising a metal, such as zinc or tin, are not discarded.

According to a fourth possibility of the invention, said printing is applied to form a mask on, in or under said layer of synthetic material, wherein this mask allows a selective treatment of the layer of synthetic material, for example, by a removal of material and / or treatment of deposition of material, in such a way that said mask determines the pattern of the recesses and / or projections thus obtained. Before said selective treatment, a selective curing treatment can be carried out by means of the same mask or a part thereof. For example, by means of the mask, a selective UV or electron beam curing of a varnish layer or another layer of synthetic material can be uniformly obtained. After having carried out the treatment, the mask and the less solidified part of the synthetic layer can be removed or not by any suitable material removal technique for this, for example, a technique in which it is brushed and / or sucked the mask, possibly together with a non-solidified part of the synthetic material layer. According to preferred embodiments of this fourth possibility, examples of the invention are obtained. According to a subordinate possibility of this fourth possibility, the mask is formed by performing said printing on a sheet or band of material or sheet of separated material, wherein preferably this sheet becomes substantially transparent or translucent. Such a sheet, which is provided with a print, can be applied, for example, to selectively block UV or electron radiation, when it is applied between the layer of synthetic material to be cured and the source of radiation. It is clear that, in the above text, by translucent or transparent it is understood that these parts of the sheet are permeable to the radiation that is applied when curing the layer of synthetic material.

It is noted that a method, such as in the third possibility of the invention mentioned above, in which the structure of a mechanical press element is formed in line and / or at the same time as the formation of the recesses in the surface of a panel, form with such a special embodiment of the invention, in which the structure of the press element is then obtained by means of a print. Such a press element can be made, for example, as a tape, a cylinder or a flat plate and can be composed substantially of metal, such as a steel alloy or a copper alloy, or substantially of synthetic material, such as silicone or melamine resin. Instead of an impression not in accordance with the invention, the structure can be composed, for example, by means of material growth or material deposition techniques, such as selective laser fusion or sintering, stereolithography or the coating. According to yet another possibility, material removal technologies can also be used, wherein a layer of renewable material disposed on the press element in question is then preferably used, in such a way that the structure of the press element can occur several times. According to another possibility, the respective press element comprises a mechanism that allows altering the structure of the surface thereof. This possibility is particularly useful for forming larger prints, such as joint prints, bevels or chamfers. By "at the same time and / or in line", it is understood that the press element on which the respective structure is formed, preferably at the same moment, is also applied at least partially to form a relief on the surface of a panel .

Preferably, another structure part of the press element is applied when the relief is provided in the synthetic material, different from that formed on the press element at the same time. Preferably, a mechanical press element is used in the form of a belt or band, whereby it preferably performs a continuous movement, for example, since this press member is transported along rollers, such as press rolls. A tape or band has the advantage that it can have a surface considerably larger than the surface of the coated panel. This makes it possible to maintain a sufficiently large distance between the place where the parts of the structure are formed and the place where other parts of the structure come into contact with the layer of synthetic material.

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The step of providing a relief in the synthetic material can be carried out in various possible ways. According to a first possibility, the synthetic material is placed on the panel before the relief is made in the layer of synthetic material. According to a second possibility, the synthetic material can also be provided with a relief before the layer of synthetic material thus structured is arranged on the panel. Thus, for example, it is possible for the layer of synthetic material to be arranged on an already structured part of the press element and for the layer of synthetic material thus formed to be carried or transferred to the panel. For example, one can work substantially with the method known as such from WO 2007/059967. In the method of this international patent application, a layer of varnish is provided on a web of structured material, after which the layer of synthetic material thus formed is transferred to the panel, where a band of pre-structured material is used. Instead of working with such a band of pre-structured material, a band of structured material is used in line and / or at the same time.

According to the special embodiment of the invention, the structural part formed in line and / or at the same time can be applied one or more times to provide a relief to the synthetic material. It is also possible that, in the case of reusing the press element in question, the parts of the structure are formed again after this part has been applied to form the relief of one or more panels. In addition, it is possible that the press element is intended for one use only.

A method with the characteristics of the special embodiment generally has the advantage that a large variety of reliefs can be manufactured with the same press element. In addition, it is possible to change without problems between different desired structures.

A method, not according to the invention, for manufacturing coated panels of the type comprising at least one substrate and an upper layer with a pattern, said upper layer being disposed on this substrate, wherein the method for making the upper layer comprises the less two steps, namely a first step, in which a layer of synthetic material is disposed on the substrate, and a second subsequent step, in which a relief is provided on the surface of said layer of synthetic material, with the feature that said relief comprises a pattern of recesses and / or projections, wherein this pattern is obtained at least partially by increasing and / or locally decreasing the volume of said upper layer and / or the substrate.

By "locally", it is understood that the entire top layer does not increase or decrease uniformly in volume. Here, this can be related to very limited local variations of increase and / or decrease in volume. For example, when viewed globally, a uniform volume increase can be observed on the surface of the upper layer, while at the edges a smaller volume increase occurs locally, or even a volume decrease occurs, to form more located edges. below which may serve, for example, as imitation of a joint, a chamfer or a layer of sunken varnish. According to another example, when viewed in a global manner, a uniform increase in the volume of the surface of the upper layer can be observed, while locally there is a smaller increase in volume or a decrease in volume to form recesses that mimic the presence of wood pores or other local irregularities.

It is clear that, according to the above preferred embodiment, the relief is obtained only after the respective part of the synthetic material has already been arranged. Thus, to apply the synthetic layer itself, techniques that are suitable for coating flat substrates can be chosen, which considerably simplifies such a method and limits or even eliminates the risk of unwanted inclusions forming, such as inclusions. of air, in the layer of synthetic material.

The increase in volume can be obtained in any way. For example, it can be created as a result of a chemical reaction, in which a gaseous substance is formed in the upper layer, which takes on a volume larger than the actual matter of the upper layer.

Preferably, the increase in volume is related to at least one increase in the volume of said layer of synthetic material. Preferably, this layer of synthetic material is located above said pattern and becomes transparent or translucent. Preferably, the synthetic layer forms the upper side of the coated panel. However, it is also possible that there are additional additional finishing layers in the plastic layer, such as one or more lacquer layers, whether or not they contain hard particles, such as aluminum oxide particles. It is clear according to the invention that the synthetic layer can also be placed under said pattern or can form part of this pattern, wherein the layer can thus show any color.

According to a further preferred embodiment, said increase or decrease in volume is carried out in a controlled manner, for example, since it is carried out against a mold, such as against a structured flat press plate or against any other structured press element, in where the structure of this press element is related to the negative, or approximately the negative, of a part of the relief that is made on the surface of one or more of the respective coated panels.

According to another preferred embodiment, the relief formed by means of a decrease or increase in volume is terminated with a technique of removing and / or adding material, such as laser milling or stereolithography.

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It is also possible that the increase or decrease in volume manifests on the surface of the substrate. Such an embodiment can be obtained, for example, because the expandable material is present on the surface of the substrate or on this substrate. For example, wood fibers in a layer on the surface of an MDF or HDF board may be provided with expandable material. According to a variant variant, not according to the invention, it is not necessary that the relief be made after providing a layer of synthetic material. By means of this MDF / HDF of the invention or other wood-based board, many new possibilities for the manufacture of panels with structure are effectively created. According to this variant of deviation, the coated panel can be substantially obtained, for example, by performing the following steps in any desired sequence: locally expanding a wood-based substrate, for example, according to any of the possibilities also described herein. to expand or not locally a layer of synthetic material, providing a pattern and possibly providing a transparent or translucent protective layer.

According to still another preferred embodiment, the present invention relates to a method for manufacturing coated panels of the type comprising at least one substrate and an upper layer with a pattern, said upper layer being disposed on this substrate, wherein the method for performing the upper layer comprises at least two steps, namely a first step, in which a layer of synthetic material is provided on the substrate, and a second subsequent step, in which a relief is arranged on the surface of said layer of synthetic material, with the characteristic that said relief comprises a pattern of recesses and / or projections, wherein this pattern is obtained by providing a mask on said layer of synthetic material and subsequently carry out a treatment of elimination and / or deposition of material on said layer of synthetic material, wherein said mask at least partially determines said pattern.

The application of a mask to add material selectively to said layer of synthetic material and / or remove it from it leads to new possibilities for realizing a relief on the surface of a coated panel. To apply a mask, a printing technique is used, such as ink jet printing, according to the features of the invention, more particularly the fourth possibility. Preferably, a technique similar to that applied to perform said motif is applied as a printing technique. In this way, a mask corresponding to the motif can be realized in a simple manner, whose mask then, in turn, can result in a relief corresponding to the motif. Preferably, a printing technique is applied which has approximately the same resolution as the printing technique with which the pattern is made, in such a way that the relief finally obtained can be made as finely as the pattern.

It is clear that, in the previous case, the relief is only obtained after the respective part of the synthetic layer has already been applied. Thus, for the application of the synthetic layer itself, techniques that are suitable for the coating of flat substrates can be chosen, which considerably simplifies such method and limits the risk of unwanted inclusions, such as inclusions, forming. of air, in the synthetic layer, or even that risk is discarded. However, the mask as such may possibly be provided before that layer of material.

Preferably, said mask is composed of or consists of means which are resistant against said techniques of material removal and / or deposition of material, in such a way that the respective technique can in fact be applied selectively in the places where the mask is not present or leave an opening. The opposite is also possible, namely that the respective technique is only active there, where the mask is present.

As a material removal technique, for example, a chemical corrosion technique may be applied, which acts locally on the synthetic layer, or a mechanical erosion technique, such as sandblasting or shot blasting. It is also possible that at least one suction treatment is applied for the material removal technique. This last technique is ideally suited when the mask or a part thereof is applied to selectively cure said layer of synthetic material, wherein preferably the parts of the synthetic layer which are located below the masking material are not solidified or they are less so.

For example, stereolithography can be applied as a technique of material deposition or material growth, or a spray technique, such as injection molding, or an immersion technique, wherein the material is then adhered there preferably where the Mask is absent or open.

The mask can be removed from the layer of synthetic material once the relief has been made. However, it can also be maintained in the final coated panel and form part, for example, of the final relief or the final pattern. As a material deposition technique, a technique can also be applied in which at least the mask adheres permanently to the layer of synthetic material. When the mask is to be at least partially maintained in the final coated panel, the color of the mask can be in tune with the desired appearance of the decorative side of the final coated panel.

It is possible that the mask, instead of being made on the panel, is done separately or, in other words, it is carried out as an existing entity as such. For example, it is possible for the mask to comprise a separate sheet or to consist of it, wherein this separate sheet or any other sheet of separated material is made preferable and substantially transparent or translucent, however, it is provided with masking portions.

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that resist said treatment of elimination and / or deposition of material or, in fact, only allows the synthetic material, which is located under the masking parts, to be exposed to a greater extent to these treatments.

According to a particular embodiment, it is possible to provide a plurality of masks one behind the other and possibly one on top of the other. By means of this embodiment, it is possible to realize a greater variety of relief characteristics. For example, such a technique can be applied to achieve deeper and / or three-dimensional structures. This technique also makes it possible to form recesses and / or projections with oblique edges, and allows forming recesses and / or projections with a width-depth, width-height ratio, respectively, which is less than 1 or even less than 0.75 or less.

As is evident from several preferred embodiments, it is possible that, between said first step, in which a layer of synthetic material is applied, and said second step, in which a relief is applied on the surface of the layer of material synthetic, at least one intermediate step is performed, wherein said layer of synthetic material is at least partially cured. This curing is preferably carried out selectively, and even better in a manner that is determined at least partially by a part of said mask.

As already mentioned, it is possible to differentiate substantially between two types of masks, namely a first type, in which the masking parts of the mask resist said treatment of elimination and / or deposition of material, and a second type in the that the masking parts of the mask are, in fact, concerned that the synthetic material located beneath the masking parts is exposed to a greater extent to these treatments. Preferably, the latter can be carried out by executing a cure of the layer of synthetic material by means of the same mask, for example, by means of UV or electron beams, or by means of heat, wherein the masking portions then form preferably a screen for the radiation and / or the heat in question. In this way, the less solidified parts can be exposed to a greater extent to the treatment to be carried out later, for example, a material removal treatment.

It is evident that the material that is applied to realize the masking parts of the mask must adapt to the function required of them. For example, wax or paraffin may be used.

Preferably, said mask is formed in line and / or at the same time with the step of applying the relief in the synthetic material. Preferably, another masking part of the mask is applied when the relief other than that formed at this same moment is formed. Preferably, in this case a mask is used, which is realized as an entity constituted as an existing entity as such, for example, a mask in the form of a tape or band, where preferably it performs a continuous movement, for example, because this mask It is transported along rollers, such as press cylinders.

It is clear that the invention also refers to panels that are obtained according to a method with the characteristics of the invention.

For the substrate of the coated panel of the invention, use is preferably made of a substrate comprising a wood-based material, such as MDF or HDF

Preferably, the coated panel refers to a panel, which motif relates to a printed pattern, which is preferably obtained by making a print directly or indirectly on said substrate.

It is clear that the coated panel, which is obtained by a method with the features of the invention, shows on its surface a relief that is obtained by means of a technique according to the invention.

According to another particular embodiment, the invention relates to a method for manufacturing coated panels of the type comprising at least one substrate and an upper layer with a printed pattern, said upper layer being disposed on said substrate, wherein the method for the upper layer comprises at least two steps, namely a first step in which a layer of synthetic material is provided on the substrate, and a second step in which a relief is provided on the surface of said layer of synthetic material, characterized in that said relief comprises a pattern of recesses and / or projections, in which this pattern is determined at least partially by means of a digital technique.

It is clear that the printing of the invention can be obtained by means of a digital technique, for example, an impression provided by an ink jet printer.

Furthermore, it is clear that said digital technique can also be performed on a transfer element or mechanical press element, in which preferably it is carried out in line and / or at the same time with the formation of the relief.

According to the invention, said layer of synthetic material preferably extends substantially over the entire surface of the substrate. In this way, a relief or structure can be obtained over the entire surface of the structure. Preferably, said layer of synthetic material also extends in the coated panel finally formed on substantially the entire surface of the substrate. Therefore, preferably, the

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material of this layer of synthetic material will also remain present in the deeper structural parts of the upper layer. In this way, it is possible to obtain good protection for the reason.

It is noted that the layer of synthetic material, which is mentioned in the invention, preferably refers to a layer of translucent or transparent synthetic material, which is located on said motif and thus protects this motive against wear, at least in certain cases. measure. In this case, it is possible for the synthetic layer to form the surface of the final coated panel. However, it is also possible that additional finishing layers are arranged on the respective synthetic layer, such as, for example, a UV hardening, an electron beam hardening or another layer of varnish, which preferably comprises hard particles, such as ceramic particles with an average particle size of less than 200 microns. Clearly, it is not excluded that the layer of synthetic material is located under the motif instead of the previous one, or that it is formed by the motif or a part thereof, in which case it does not necessarily have to be translucent or transparent.

For the synthetic material layer itself, use can be made of synthetic material comprising aminoresin, such as melamine resin, PVC (polyvinyl chloride), polyethylene, polypropylene, polyurethane or polystyrene.

Preferably, the method according to the invention is applied to manufacture coated panels, wherein said substrate comprises a wood-based material, such as MDF or HDF. Such a material can easily be provided with a ground flat upper surface, such that possible irregularities of the respective upper surface do not interfere with the structure or relief made on the upper surface. In order to avoid such an influence on the structure, it is also possible to use primer layers comprising a filling material, with which possible irregularities in the upper surface of the substrate can be filled.

When, according to the invention, a layer of synthetic material, such as a PVC layer, is combined with a wood-based substrate, such as an MDF or HDF substrate, an adhesion layer is preferably provided between the layer of synthetic material and the substrate. Such an adhesion layer may consist, for example, of a sheet of material, which on one side is provided with aminoresin, such as the melamine resin, and on the other side is provided with the respective synthetic material, for example, PVC With respect to the melamine resin, it is known to adhere correctly to wood-based substrates, such as MDF or HDF. Possibly, the reason may already have been printed in advance on this material sheet.

Preferably, said reason, according to the invention, refers to a printed pattern, which is preferably obtained by making a print directly or indirectly on said substrate. Indirect printing can be obtained, for example, by printing on one or more layers of primer already disposed on the substrate. According to the invention, however, it is not excluded, of course, to work with a pattern that is printed on a sheet of flexible material, whose sheet of material then is or will be completely or partially disposed on the substrate. Preferably, said reason has been obtained by printing by an ink jet printer with one or more print heads.

It is clear that the steps discussed in the invention can be performed on larger boards, from which the final coated panels are formed, for example, by subdividing these larger boards with a sawing machine, as well as panels that already show the approximate dimensions of the final coated panels. For a quick reaction to an order, and to exclude redundant supplies, it is advantageous to make the structure and / or the reason as late as possible in the manufacture. In such a case, they are preferably and directly disposed on panels that already have roughly or completely the dimensions of the final coated panels. In that same case, the respective panels may also already be provided with possible edge finishes, such as milled coupling means or other profiled edge parts. Of course, it is not excluded that such profiled edge parts are provided later during manufacture. Providing a structure or a relief panel per panel has the advantage that the risk of this structure disappearing considerably, for example, because it is ground, or cut, or otherwise removed, even when this is related, for example, with relatively restricted structures located on the edge of the panel, such as bevels with a depth of less than 1 millimeter.

Preferably, the position of the relief or structure, according to the invention, refers to a final edge or a final corner point of the coated panel, whether or not this edge is to be obtained. This preferred embodiment can be realized in the simplest manner when the substrates already have the respective final corner edge or tip; however, it is not discarded that, even if the substrates do not yet have this edge or end-corner point, an alignment is still made with respect to the edge or end-corner point to be formed, for example, because they are provided other means of reference, which adopt a position that refers to the respective final corner edge or tip. For example, the present preferred embodiment allows to obtain symmetrical structures, such as imitations of tiles or imitations of floor parts with a lower edge of two or four sides, in a uniform manner, where then the width is preferably made equal or approximately equal of the lower edges, on opposite sides of the coated panels.

Furthermore, it is clear that, according to the invention, a structure corresponding to said motif is preferably obtained.

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In general, it is observed that the relief, which is discussed in the invention, can also be restricted in depth, such that, in reality, it refers to a pattern with different degrees of brightness. For example, by means of a technique, in which sandblasting is applied as a material removal technique, matt spots can be made on the surface of the coated panel. In addition, it is also noted that the relief is present tangibly on the surface of the final coated panel. However, according to certain embodiments, it is not excluded that the respective relief is internally present in the upper layer of the coated panel and is not tangible, although it is visibly present on the surface of the coated panel. Such an embodiment can be obtained when by means of the techniques of the invention a relief is imparted to the motive itself, while, consequently, the surface of the coated panel becomes substantially or completely flat. As already mentioned, by means of such relief depth effects effects can be obtained, which remain visible on the surface of the coated panel. Other visible effects, which are not present in a tangible way on the surface of the coated panel, are not ruled out.

With the intention of better showing the characteristics of the invention, as an example without any limiting character, some preferred embodiments are described below, with reference to the attached drawings, in which:

Figure 1 schematically represents some steps of a method with the features of the invention;

Figure 2, on a larger scale, represents a cross section according to the line ll-ll indicated in figure 1;

Figures 3 to 6, on the same scale, represent cross sections, respectively according to the lines III-III, IV-IV, V-V-, V1-V1 indicated in Figure 1;

Figure 7, on the same scale, but for a variant, represents a cross section according to line VII-VII indicated in Figure 1;

Figure 8 for a variant represents a view according to the direction F8 indicated in Figure 7;

Figure 9 schematically represents another method with the characteristics of the invention;

Figures 10 and 11 schematically represent some further steps in a method with the features of the invention;

Figures 12 to 15 represent some variants of more than one method;

Figure 16 represents another example of a method of the invention;

Figures 17 and 18 represent other variants.

Figure 1 schematically depicts some steps S1-S5 in a method for manufacturing coated panels 1. The respective coated panels 1 are of the type comprising at least one substrate 2, eg, a basic panel of MDF or HDF, and a top layer 3 arranged on this substrate 2. In the example, the upper layer 3 is composed of a plurality of layers of material 4-7, between which a layer of material 5, which shows a pattern and which, during step S2, is applied in the form of an impression 8 made directly on the substrate 2.

In a previous step S1, one or more primer layers 4 are arranged on the surface of the substrate 2 to be printed with the pattern. These layers may have the purpose of providing a smooth subsurface and / or providing a uniform or nearly uniform background color and / or an adherent undercoat for the layers of material 5-8 to be applied later, such as for the layer of material 5 with the pattern, or for layer of plastic material 7.

Figure 2 represents the result of step S1 and shows that a possible irregular surface of the substrate 2 can be made flat or approximately planar by means of said one or more layers of primer 4.

In the example, step S1 makes use of an application technique by means of one or more cylinders 9. It is clear that in step S1 of FIG. 1, other application techniques can also be applied to perform one or more primer layers 4. At the same time, it is clear that it is not necessary for the invention to apply such primer layers 4, although this may be important for the quality of the pattern. Instead of working with a primer layer 4 that is provided in liquid form, it is also possible to use a primer layer 4 comprising a sheet of material, such as a sheet of paper, and which is disposed on the substrate 2. dry or almost dry.

As mentioned above, in step S2 of figure 1, a pattern is made by an impression 8 which is made directly on the substrate 2 or on a primer 4 already arranged on the substrate 2. The pattern obtained relates to a wooden pattern extending over the entire length of the rectangular oblong panel 1. Of course, the invention is not restricted to such reasons.

In this case, to provide the printed pattern, use is made of an inkjet printer 10 with one or more printheads. For example, you can make use of the techniques and devices that are known as such by the

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EP 1 872 959, in which, for example, such a battery of ink jet print heads is arranged one after the other and side by side in such a way that the entire surface of the panel 1 can be covered by a multicolor print. It is evident that the present invention for step S2 is not restricted to ink jet printing techniques, nor to patterns printed directly on substrate 2.

Figure 3 represents the result of the printing 8 made directly on the substrate 2, in this case, on a primer layer 4 already located on the substrate 2.

In step S3 of figure 1, an additional print 6 is provided on the printed pattern. This refers to an impression 6 with an agent that prevents expansion. The print 6 is made with a pattern that will determine the final structure or relief of the coated panel 1. In this document, the pattern covers only particular locations in the printed pattern and, therefore, preferably does not extend over the entire surface of the printed pattern. final coated panel 1. In this case, the pattern forms a mask providing the edges 11 of the panel 1, as well as certain locations 12 on the surface of the panel 1 with such an agent preventing expansion. In this case, the locations 12 on the surface of panel 1 correspond to wooden flowers or wooden ribs present in the wood pattern and will lead to recesses present in the final panel 1, which mimic the pores of the wood.

Figure 4 clearly shows once again the locations 11-12 of the print 6 provided in step S3.

In step S3, it is shown that the print 6, which determines the relief or structure, is provided by a digital printing technique, such as by means of an inkjet printer 10. It is clear that it is not excluded that the 6 or the agent that prevents the expansion can be applied in another way.

In step S4 of figure 1, a layer of synthetic material 7 is applied. Such a layer of synthetic material 7 preferably consists of a transparent or translucent material and preferably preferably extends over the entire panel 1 in question. In the example, a cylinder 9 is shown to apply such a layer. However, it is clear that this layer of synthetic material 7 can be provided in any way. It is also possible that in step S4 a plurality of plastic layers 7 placed one on top of the other, whether or not they are of the same type, are applied. Preferably, wear resistant hard particles are also provided in the plastic layer 7. For example, they can be mixed or knitted in advance in the synthetic material or in the plastic layer 7, or they can be spread in the material layer. synthetic already arranged 7 or deposit them in another way.

Figure 5 shows the result obtained after step S4.

In step S5 of figure 1, a relief is provided on the surface of the synthetic layer 7 applied in step S4.

Figure 6 shows that here a coated panel 1 is obtained which shows a pattern of recesses 13 and projections 14 on its surface, where this pattern is determined at least partially by means of printing 6 with an agent that prevents the applied expansion in step S3. This structure is obtained because the layer of synthetic material 7 is activated in step S5 and begins to expand. This activation can be obtained, for example, by heating the layer of synthetic material 7 by means of a hot air oven 15, an infrared oven or by radiation, such as UV or electronic radiation.

Figure 6 shows that in places where, in step S3, the agent that prevents expansion or reduces expansion is applied, said expansion has occurred to a lesser extent or has not occurred at all. In these places, there are recesses 13 in the surface of the layer of thickened synthetic material 7. Thus, in the example, bevels 16 have been obtained at the edges 11 of the coated panel 1, and recesses 13 have been obtained. on the surface of the panel 1 to imitate pores of wood 17. It is evident that the technique of the invention can also be applied to obtain only the bevels 16, or to obtain only imitations of wood pores 17 or to obtain other structures.

Figure 6 also shows that the obtained recesses 13 can have a structure with strong rounded portions 18.

Figure 7 shows a possibility of obtaining sharper structures. In this case, when the layer of synthetic material 7 is expanded, in step S5 a forming mold 19 can be applied, against which the layer of expanding plastic material 7 is raised. Such a technique can be of interest to form bevels. sharper 16. In the example shown, the forming mold 19 is a substantially planar press element. However, one can also work with one or more press cylinders or casting wheels.

Figure 8 represents another possibility to obtain sharper structures, such as the sharp bevels 16. In this document, the one or more impressions 6 mentioned above, which determine the structure, are made with a so-called degigrade, in which the intensity or the amount of applied agent of the impression 6 varies according to the depth that one wishes to obtain in that place. It is evident that this printing technique can be combined or not with the technique shown in Figure 7.

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The application of such deggrede also has advantages in all embodiments in which the relief is determined at least partially by means of a preferably digital printing.

Figure 9 represents a preferred embodiment of the invention. Here, the third possibility mentioned in the introduction applies for this purpose. Here, by means of an impression 6, a structure is formed on a transfer element 20, in this case on a cylinder. This structured cylinder is applied to form the relief on the surface of the coated panel 1. The formation of the impression 6 on the transfer element 20 is carried out in line and at the same time as the recesses 13 or the relief are formed in the layer synthetic material 7 of the coated panel 1. To form the structure on the transfer element 20, a digital technique is preferably applied, such as a printing technique by means of an ink jet printer 10, in which, for example, varnish or wax is deposited in a pattern on the cylinder. Furthermore, in figure 9 it is shown that the structure of the cylinder can be continuously renewed since the part of structure already used of the cylinder is removed, for example, by means of a scraping device 21, and replaced by a part of structure newly willing It is clear that also in such an embodiment a degrade may be applied, as described by means of Figure 8.

Figure 10 represents another example of a method, in which a mask 22 is provided in the layer of synthetic material 7 and, subsequently, a material deposition treatment is carried out on the layer of synthetic material 7. In this case, the The material deposition treatment is related to the coating of the surface of the panel 1 by means of a liquid synthetic material 23. In this document, the mask 22 is chosen in such a way that the synthetic material 23 adheres only to those places where it does not the mask 22 is arranged.

Figure 11 shows the result of this method after the mask 22 has been removed and not the adherent part of the synthetic material 23. On the surface of the panel 1, a relief of the recesses 13 and the projections 14 is obtained. that this pattern is determined by said mask 22.

Furthermore, it is clear that also when applying printed masks, it may be advantageous to apply the so-called "degrades", as described by FIG. 8.

Figure 12 represents a variant of the method shown in Figure 9, in which the method comprises at least the steps of providing a layer of synthetic material 7 on the substrate 2 and providing in this synthetic material a relief by means of a mechanical press element structured 20. In this document, the structure of the press member 20 is formed in line and at the same time as the step of providing a relief in the synthetic material. In the example, the press element 20 refers to a roller. The difference between the embodiment of Figure 12 and the embodiment of Figure 9 is that now the synthetic material is provided with the relief before arranging the layer of structured synthetic material 7 on the panel 1. That is, the synthetic material is disposed on an already structured part of the press element 20 and the layer of synthetic material 7 thus formed is transferred at least partially on the panel 1.

Figure 13 shows another variant thereof, wherein for the press element 20 instead of the roller, a press belt or a press band is used, which is transported on rollers 24 towards the panel 1. The press element 20 is of the type that can be arranged on a supply roll 25. This can relate, for example, to a sheet, such as a synthetic sheet, a sheet of paper or a metal sheet, such as aluminum foil. In dashed line 26, it is shown that it is also possible to work with an endless belt, where then, preferably, a scraping device 21 is provided, so that a part of the structure already applied can be removed. In the case of such an endless belt, for example, a metal belt can be used.

Of course, the arrangement of Figure 13 can also be applied when, as is the case in the example of Figure 9, the synthetic material is arranged in the panel before embossing in the layer of synthetic material 7. The figure 13 also represents that it is possible to perform a forced drying on the synthetic layer by means of any drying station 27. As a drying station 27, for example, a hot air oven, a UV heating element can be applied. or an infrared heating element.

It is noted that it is possible to structure the press element 20 of Figure 13 on the other side 28 and obtain a similar effect. Such an embodiment is not shown here, however, it has the advantage that the risk of the printing 6 also partially transferring to the panel 1 is minimized.

The arrangement shown in Figure 13 corresponds to the arrangement shown in WO 2007/059667, with the difference, however, that instead of a pre-structured material web, a press member 20 or a band is applied of press structured online and at the same time.

Figure 14 represents another embodiment in which this risk is minimized. Here, the process shown in FIG. 12 is substantially applied, however, with the difference that a sheet 29 is applied between the press element 20, whose press element is structured in line and at the same time. This sheet 29 is deformed by means of the structured press member 20, as a result of which a structure of recesses 13 and projections 14 is obtained in the layer of underlying plastic material 7.

It is also noted that the embodiments of FIGS. 13 and 14 have the advantage that only the band-shaped press element 20, the sheet 29, respectively, come into contact with the synthetic material of the film layer.

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synthetic material 7. This is particularly advantageous when such a layer of synthetic material 7 comprises wear-resistant particles, such as aluminum oxide. In this way, that is, the remaining parts of the arrangement, such as the rollers 24, are maintained without rapid wear.

Figure 15 represents another embodiment similar to the example of figure 12, where, however, the print 6, which determines the structure or at least a part thereof, is transferred to the layer of synthetic material 7. The technique of Figure 15 can possibly be applied to form a mask 22, which can be applied, as described in the introduction.

Figure 16 represents another example of a method with the features of the invention. In this document, a mask 22, which initially had been arranged on the layer of synthetic material 7, is printed on the layer of synthetic material 7 by means of a press treatment before applying said treatment for removing material and / or deposition of material. In this case, this is related to a material removal treatment, namely, a S6 brush treatment. Possibly, a drying treatment can be applied on the layer of synthetic material 7 before said material removal treatment, in such a way that the actual layer of synthetic material 7 is sufficiently strong against this treatment S6. Such a drying treatment is not shown here, however, it can be understood that it is similar to that of the drying station 27 of Figure 13.

Figure 17 represents another example. In this case, the mask 22 is of the type in which the masking parts allow the synthetic material of the plastic layer 7, which is below, to be exposed to a greater extent to the material removal treatment of step S6, in this case, a suction treatment. In the example, this is done because the masking parts 30 comprise a material that is impermeable or at least offers some protection against UV radiation from the drying station 27, such that the part 31, located there below, of the layer of synthetic material 7 solidifies a little or nothing. Those parts 31 of the synthetic layer 7 are then removed in step S6, in this case, together with the mask 22, by means of the suction treatment represented here. It is possible for the mask 22 to be removed in a separate step, preferably before removing the uncured or slightly solidified parts 31 of the plastic layer 7.

It is clear that the mask 22 of the example of figure 17 can be realized by means of a possible digital printing 6.

Figure 18 represents an example in which a mask 22 is used, which is created as an existing entity as such. In this case, the mask 22 is composed of a substantially translucent or transparent sheet 29, which, by means of an imprint 6, is provided with masking parts 30. In the example, this, as is the case in Figure 17, is related to the masking parts 30, which cause the parts 31 of the synthetic material, which are located below the masking parts 30, to be exposed to a greater extent to the material removal treatment of step S6, in this case, a suction treatment. This sheet

29 is disposed between the radiation source, in this case, the drying station 27, and the layer of synthetic material 7 in a step preceding the material removal treatment, at which location the masking portions

30 form a selective screen, for example, for the UV radiation emitted by the drying station. Figure 18 also represents an example of a method in which the mask 22 is removed from the layer of synthetic material 7 in a separate step. In this case, this is done by moving the sheet 29 away from the layer of synthetic material 7 before the parts 31 not solidified at all, or solidified only a little, are exposed to the material removal treatment of step S6.

It is clear that the masking parts 30 may be arranged on either side of the sheet 29, or may even be arranged on both sides of the sheet. The illustrated embodiment has the advantage that the masking parts 30 can be removed more easily from the plastic layer 7. Possibly, the side of the sheet 29 which is in contact with the layer of synthetic material 7 may be provided with a release layer, for example, with a release layer comprising silicone and / or Teflon.

It is clear that the embodiments of Figures 17 and 18 also form an example of a method in which the mask is formed in line and at the same time as the step of providing the relief in the synthetic material. In this case, subsequently, another masking part 31 is applied when the relief is provided in addition to that formed at the same moment by means of the ink jet printer 10.

According to a variant not shown, a plurality of masks 22 can be provided one after the other and / or one on top of the other. In the example of Fig. 16, 17 or 18, an additional mask 22 can be applied before or after a front mask 22 is printed on the plastic layer 7 by means of said press treatment, or after said mask 22 has already been removed. By a good choice of the various masks 22, the recesses 13 and / or the projections 14 can be made with oblique walls and / or with different depths.

It is clear that the results of the methods according to the invention shown in Figures 6, 7 and 9 to 18 can be terminated even with one or more finishing layers, such as varnish layers.

It is noted that the thickness of the layers of material and the substrates shown in Figures 2 to 7 and 9 to 18 is represented only schematically and does not include any restriction. However, it is clear that the thickness of

the top layer can be restricted to several tenths of millimeters, while the thickness of the substrate can vary from 5 to 15 millimeters or more.

It is important to bear in mind that, according to the invention, relatively rigid panels are manufactured and coatings can not be rolled up. The rigid panels have the advantage that they can be easily provided with connection means, for example screws, pins or mechanical coupling means, which allow two such panels, for example, floor panels, to be coupled to each other, for example. example, milling the profiles of such coupling means on said substrate. Such coupling means and milling techniques are known as such by WO 97/47834 or DE 20 2008 008 597 U1. Due to its stiffness and the presence of coupling means, the manufactured coated panels are simple to install and do not require gluing with the underlying layer 10.

The present invention is not limited in any way to the embodiments described above; on the contrary, such methods and panels may be made according to various variants, without departing from the scope of the present invention, as defined in the appended claims.

Claims (11)

5 10 fifteen twenty 25 30 A method for manufacturing coated panels (1) of the type comprising at least one substrate (2) and an upper layer (3) with a pattern, said upper layer being disposed on said substrate (2), wherein the method for performing the upper layer (3) comprises at least two steps, namely a first step (S4), in which a layer of synthetic material (7) is arranged on the substrate (2), and a second subsequent step (S5) ), in which a relief is arranged on the surface of said layer of synthetic material (7), in which said relief comprises a pattern of recesses (13) and / or projections (14), characterized in that this pattern is determined and it is achieved at least partially by means of a printing technique that performs one or more impressions (6). Method according to claim 1, characterized in that said printing (6) is placed under said layer of synthetic material (7), the respective printing (6) being arranged in a step (S3) preceding said first step (S4) ). Method according to claim 1, characterized in that said printing (6) is placed above said layer of synthetic material (7), the respective printing (6) being arranged in a step following said first step (S4). Method according to any of the preceding claims, characterized in that said printing (6) is carried out by means of an expandable agent or that prevents expansion. Method according to claim 1, characterized in that said printing (6) is applied to form a structure on a transfer element (20) and the transfer element (20) thus structured at least partially is then applied to form recesses (13) in said layer of synthetic material (7). Method according to claim 5, characterized in that said printing (6) is carried out with a printing agent, and that it is the printing agent itself that forms the structure of the transfer element (20). Method according to claim 6, characterized in that a wax or varnish is applied to said printing agent. Method according to claim 1, characterized in that said printing (6) is applied to form a mask (22) on, in or under said layer of synthetic material (7), this mask (22) allowing a selective treatment of the layer of synthetic material (7). Method according to claim 8, characterized in that said mask (22) is formed by making said impression (6) on a band of separated material. Method according to any of the preceding claims, characterized in that said printing technique is a digital printing technique. Method according to any of the preceding claims, characterized in that the same printing technique is applied both to form the pattern and to form said one or more impressions (6).