RU2643975C2 - Digital printing with binding - Google Patents

Digital printing with binding Download PDF

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Publication number
RU2643975C2
RU2643975C2 RU2015104864A RU2015104864A RU2643975C2 RU 2643975 C2 RU2643975 C2 RU 2643975C2 RU 2015104864 A RU2015104864 A RU 2015104864A RU 2015104864 A RU2015104864 A RU 2015104864A RU 2643975 C2 RU2643975 C2 RU 2643975C2
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Russia
Prior art keywords
surface
powder
pigments
binder
method according
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RU2015104864A
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Russian (ru)
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RU2015104864A (en
Inventor
Дарко ПЕРВАН
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Сералок Инновейшн Аб
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Priority to US201261675971P priority Critical
Priority to US61/675,971 priority
Priority to SE1250898-2 priority
Priority to SE1250898 priority
Application filed by Сералок Инновейшн Аб filed Critical Сералок Инновейшн Аб
Priority to PCT/SE2013/050898 priority patent/WO2014017972A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/06Veined printings; Fluorescent printings; Stereoscopic images; Imitated patterns, e.g. tissues, textiles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/006Patterns of chemical products used for a specific purpose, e.g. pesticides, perfumes, adhesive patterns; use of microencapsulated material; Printing on smoking articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/0081After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/009After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using thermal means, e.g. infrared radiation, heat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00Sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2451/00Type of carrier, type of coating (Multilayers)
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment 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
    • B05D3/04Pretreatment 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 gases
    • B05D3/0406Pretreatment 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 gases the gas being air
    • B05D3/042Directing or stopping the fluid to be coated with air
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment 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
    • B05D3/06Pretreatment 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
    • B05D3/061Pretreatment 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.
    • B05D3/065After-treatment
    • B05D3/067Curing or cross-linking the coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers

Abstract

FIELD: printing industry.
SUBSTANCE: invention relates to a method and equipment for digital image formation by coating layer of powder containing coloured pigments, on the surfaces, binding a part of powder and removing unbound powder from the surface. Method of forming digitally printed images (P) using coloured pigments on surface of construction panel includes the stages of scattering dry coloured pigments on the surface, binding a part of dry colour pigments with surface, removing inbound dry coloured pigments from the surface in such a way that through the associated dry colour pigments forming a digitally generated image and applying heat and pressure to the surface of the construction panel. Wherein, the step of binding the said part of dry colour pigments to the surface comprises applying a liquid substance by means of a digital coating head.
EFFECT: expanded operating capabilities.
24 cl, 27 dwg

Description

FIELD OF THE INVENTION

The invention relates, in general, to the field of digitally created decorative surfaces, preferably building panels, such as floor and wall panels. The invention relates to methods and equipment for producing such decorative surfaces.

Application area

Embodiments of the present invention are particularly suitable for use in floors that can be formed from floor panels comprising a core, a decorative layer and a transparent wear-resistant structured layer on top of the decorative layer. Therefore, the following description of the known method, the problems of known systems, as well as the objectives and features of the invention, will be given as a non-restrictive example oriented to this field of application, and in particular to decks similar to ordinary laminate or decks with an elastic surface layer .

It should be emphasized that embodiments of this invention can be used to obtain a digital image on any surface, but flat panels, for example, such as building panels in general, with preferred wall panels, ceilings, as well as furniture components and similar components, which have large surfaces with decorative patterns. The method is also applicable for printing on any surface, which may be flat, curved, structured or similar, on paper, films, textile materials, metal, wood veneer, cork layer, polymer material, and similar surfaces.

BACKGROUND OF THE INVENTION

Most of all laminate floors are made in accordance with the manufacturing method, commonly referred to as the Direct Pressure Laminate (DPL) production method. The floors made in this way contain a core of a fiberboard 6-12 mm thick, an upper decorative surface layer of a laminate 0.2 mm thick and a lower balancing layer of a laminate, plastic, paper or similar material with a thickness of 0.1-0.2 mm.

The surface layer of a laminate floor is characterized in that its decorative and wear properties are generally obtained using two separate layers of paper stacked one on top of the other. The decorative layer is generally printed paper, and the wear layer is transparent overlay paper that contains small particles of aluminum oxide.

The printed decorative paper and overlay are impregnated with melamine-formaldehyde resins and layered on the core of a high density fiberboard (HDF) in large intermittent or continuous presses to form laminates, where the resin is cured by strong heat and high pressure, and the mentioned papers are layered on the core material. The surface structure is formed by an embossed press plate or steel tape. Sometimes, structured paper is used as a compression matrix.

Laminate floors can also be made using printing technology. One advantage is that the pressing operation can be avoided and that printed papers are not required to provide a decorative, wear-resistant surface.

Direct printed laminate floor panels contain an HDF core of the same type as DPL. Decor is printed directly on the core. The manufacturing process is quite complicated and cost-effective only with very large volumes of production. To print the decor using a multi-color printing machine with rollers that print directly onto a pre-compacted core, water-based inks are used.

Direct printing technology can be replaced by digital printing technology, which is much faster to change, so that it can be used to make cost-effective production in small volumes. The difference between these two methods lies mainly in the printing phase, where the printing rollers are replaced by a contactless digital printing process and where the desired image is applied directly to the core, previously subjected to finishing processing.

Digital printing can also be used to print on a sheet of paper, which is used in the usual production of laminates and which is layered under the influence of heat and pressure. Printing can be done before or after impregnation.

Paper and plastic films can be used as surface layers in floors, and digital printing can also be done on such materials.

Recently developed floors are of a new type - “paperless” - with hard surfaces containing a substantially homogeneous mixture of fibers, binders and wear-resistant particles.

The powder mixture may contain alumina particles, melamine formaldehyde resins, and wood fibers. In most applications, the mixture includes decorative particles, such as color pigments, for example. In general, all of these materials are preferably applied dry — like a mixed powder — to the HDF core and cured by heat and pressure to form a continuous layer 0.1-1.0 mm thick. Before pressing, the powder is stabilized with moisture and UV lamps (UV lamps) so that the powder forms an upper coating layer similar to a paper layer, and this prevents the powder from deflating during pressing. Melamine formaldehyde resin and wood fibers can be replaced with thermoplastic particles.

You can get several advantages over the known technology, especially over traditional laminate flooring, such as increased wear resistance and impact resistance, deep embossing and reduced costs.

Powder technology is very suitable for producing a decorative surface layer, which is a copy of stone and ceramics. However, it is more difficult to create designs, for example, such as the surroundings of wood. However, digital powder printing has recently been developed, and now it is possible to create very promising designs of any type by injecting printing ink into the powder and creating a digital print before pressing. The surface structure is performed in the same way as for a laminate flooring - by means of a structured press plate, steel tape or embossed matrix paper, which is pressed to powder.

Wood flooring is obtained in many different ways. Traditional solid wood floors have been developed, which are built-in floors with wood layers applied to a core made of wooden plates, HDF or plywood. Most of these floors come in the form of pre-finished floors with a wood surface, which is covered with several transparent layers at the manufacturer. Recently, wooden floorings with a digitally obtained pattern have also been made, which improves the design of the structure of wood fibers in wood species that do not have sufficient surface quality.

Several types of floors use digital printing to create decor. However, the volume of use is still very small due to the high cost of printing ink and the large capital investment in industrial printing devices. If it were possible to reduce the cost of printing ink and if it were possible to use more cost-effective equipment on an industrial scale, this would be a fundamental advantage.

Definition of some terms

In the following text, the visible surface of the installed floor panel is referred to as the “front side”, and the opposite surface of the floor panel facing the base of the floor is called the “back side”. The “surface layer" means all the layers that give the panel its decorative properties and its wear resistance.

By “imprint” is meant a decor or an image. The word “up” refers to the direction to the front side, and the word “down” refers to the direction to the back side. The word “vertically” means perpendicular to the surface, and the word “horizontally” means parallel to the surface.

By “pigments” is meant a finely divided powder of solid particles of a coloring substance.

By “dye-based printing ink” is meant a colored substance that is completely soluble in a carrier fluid, and the resulting printing ink is a true solution, completely soluble in water like sugar.

By “water-based or water-based printing ink” is meant a printing ink in which water is used as a liquid substance. Water-based fluid is a carrier of pigments.

By “solvent based printing ink” is meant a printing ink that generally contains three main constituents, such as a fluid carrier, pigments and resins. Technically, “solvent based ink” is a term referring only to the oil-based portion of the ink carrier that carries the other components in liquid form and evaporates immediately after being sprayed onto the surface.

By “UV-curable printing ink or coating” is meant a printing ink or coating that is or which, after application, is cured by exposure to UV radiation in a UV oven.

By “binder” is meant a substance that connects two particles or two materials, or contributes to this compound. The binder may be a liquid, powder-based, thermoset or thermoplastic resin and the like.

Well-known method and its attendant problems

The following describes the general technology used in the industry to provide digital printing. The methods described below can be used individually or in combination, creating a digital fingerprint or providing digital application of a substance in embodiments of the present invention.

High-resolution digital printers use bumpless printing processes. The printing device has printheads that very accurately “shoot” ink droplets from the printheads onto the substrate.

Multipass printing, also called scanning printing, is a printing method when the head of the printing device transversely moves over the substrate many times to generate an image. Such printers are slow, but one small printhead can generate a larger image.

Industrial printing devices are generally based on a single pass printing method involving the use of stationary heads of a printing device with a width that corresponds to the width of the print media. Under the heads moves the substrate for printed information. Such printing devices have a large capacity and are equipped with stationary printing heads that are aligned one after the other in the feed direction. Each printhead prints in one color. Such printing devices can be made to order for each application.

In FIG. 1a shows a single pass printing device 35 comprising five digital printheads 30a-e, which are connected by ink tubes 32 to ink containers 31 filled with inks of different colors. The printing heads for printing inks are connected by digital data cables 33 to a digital control unit 34, which controls the supply of ink droplets and the speed of the conveyor 21, which moves the panel under the print heads with high accuracy to ensure a high-quality image containing several colors.

In FIG. 1b shows the imprint P of wood fibers provided on the surface 2 of the panel. The surface of the floor panel is often embossed using a standard structure 17, which is the same for several basic decors, as shown in FIG. 1c. Improved floors use an impression 17 with a register of printed pattern P, as shown in FIG. 1d.

The typical width of an industrial printhead is approximately 6 cm, and segments of any length can be printed. Using digital printers containing several rows of print heads aligned side by side, you can print wide areas of 1-2 m in size.

To characterize resolution and print quality through a digital printing device, the number of dots per inch or DPI is used. 300 DPI is generally sufficient, for example, to print structures of wood fibers of the same quality as that used in conventional laminate flooring. Industrial printing devices can print drawings with a resolution of 300-1000 DPI, and even more, at speeds exceeding 60 m / min.

The fingerprint may be a “full fingerprint”. This means that visible print decor is created primarily through pixels of printing inks applied to the powder or applied to the surface. The color of the powder layer or the base color of the paper in such an embodiment has a mainly limited effect on the visible pattern or decor.

A fingerprint may also be a “partial fingerprint”. The color of the other - underlying - layer is one of the colors that are visible in the finished decor. The area covered by the printed pixels and the amount of printing ink used can be reduced, and due to the less use of printing ink and the larger print volume compared to the full print design, a reduction in costs can be obtained. However, a partial print is not as quickly readjusted as a full print, since it is more difficult to change the base colors than when using a full print.

The print can be based on the CMYK color principle. This is a 4-color system, including cyan, magenta, yellow and black. Mixing them together gives a color space that is relatively small, or a color palette that is relatively small. To increase this space or this palette, you can add a specific color or spot colors of the entire spectrum. Spot color can be any color. Color mixing and control is carried out using a combination of software and hardware (print processors and / or printheads).

Valinge Innovation AB has developed a new technology that enables the incorporation of a digital fingerprint into a powder layer. This new type of “digital input fingerprint” or DIP is obtained by printing into a powder that is cured after printing. The print is embedded in the cured layer, and not applied to the layer, as in the case when conventional printing methods are used. The print can be positioned horizontally and vertically at different depths. This can be used to create bulk effects when transparent fibers are used, and to increase wear resistance. Protective layers that distort the original image are not needed.

The DIP method can be used in all powder-based materials that can be cured after printing. However, the DIP method is particularly suitable when the powder contains a mixture of wood fibers, small hard particles and melamine-formaldehyde resin. The surface layer may also contain a thermoplastic material, for example, vinyl particles, which are applied to the substrate in the form of a powder. This ensures that an imprint is introduced into the particles of the vinyl powder. Even in such materials an improved design and increased wear resistance can be achieved.

To obtain high print quality and high speed printing in layers based on powders and other layers described above, it is necessary to use a suitable head of the printing device. The head of the printing device has several small nozzles that can controllably “shoot” droplets of printing inks (“Drop on demond” - DOD - ink-jet printing technology with ink dosing). The volume of each drop can be changed depending on the type of printing ink and type of head, usually in the range from 1 to 100 picoliters. You can perform printheads that can "shoot" droplets of a larger volume - up to a value of more than 200 picoliters. Some heads of printing devices can “shoot” drops of different volumes and are capable of printing within a grayscale scale. Other heads can “shoot” only drops of one - fixed - volume.

You can use different technologies to shoot drops from the nozzle.

The technology of heads of thermal printing devices involves the use of cartridges for printing with a number of miniature cameras, each of which contains a heater, all of which are created by photolithography. In order for the droplet to eject from each chamber, a current pulse is passed through the heating element, causing a rapid evaporation of the printing ink in the chamber with the formation of a bubble, which leads to a large increase in pressure, pushing a drop of printing ink through the nozzle to the substrate. Most consumer inkjet printers from companies like Canon, Hewlett-Packard, and Lexmark use thermal print heads.

Most commercial and industrial inkjet printheads and some consumer printheads, such as those made by Epson, use piezoelectric printhead head technology. Instead of a heating element, a piezoelectric material is used in the ink-filled chamber behind each nozzle. When voltage is applied, the piezoelectric material measures the shape, which leads to the generation of a pressure pulse in the fluid, pushing a drop of ink from the nozzle. Piezoelectric inkjet printing (also called inkjet piezo printing) allows the use of a wider range of printing inks than inkjet thermal printing, since there is no requirement for a volatile component and there is no question of coagulation. Many types of inks can be used, such as dye-based inks, solvent-based inks, latex inks, or UV-curable inks.

Pigment based inks are generally individually mixed with each other through the use of colored pigments and several chemicals. A pigment is a finely divided powder of solid particles of a coloring substance that is suspended or dispersed throughout the carrier fluid. The pigments used in digital printing inks have an average particle size of 0.1 microns. The typical nozzle size is about 20 microns, and this means that the pigment particle has enough space to pass through the nozzle channels in the print head. The nozzles will continue to be blocked by the printing ink itself and pigments that form clusters of particles. High-quality pigment printing ink must support the pigment suspended in the carrier fluid for a long period of time. This is difficult to accomplish, in particular at the low viscosities that are required for the printheads to function satisfactorily. Pigments have a natural tendency to settle and precipitate in a carrier fluid. In high-quality pigment printing ink, pigment subsidence usually should not occur.

Particularly suitable are water-based inks containing colored pigments, and they can provide a cost-effective way to print with high quality in many different materials. Pigment inks are generally more lightfast and more resistant to loss of original properties than dye-based inks.

Pigments do not stick to the surface. They are similar to sand particles and can be easily removed from most dry surfaces. Therefore, in order to provide a special printing ink and printing properties, a water-based carrier fluid is generally mixed with small amounts of other additives, such as binders, which provide adhesion of pigments to the surface, increase the size of the raster dots, pH level, drop formation , anti-corrosion of the print head, resistance to loss of the original properties of the ink, etc.

Color pigments as such are quite competitive in price, but the production of pigment printing inks and other printing inks for digital printing devices is very complex and expensive, and this leads to a high cost of printing ink, which is usually in the range of about 100 Euro / liter. One liter of printing ink can print about 100 m 2 of the coating if a high-quality print is applied, and this leads to costs of 1 euro / m 2 . Costs on the surface of the floors, obtained by the method of conventional printing in the case of using printing cylinders, make up only 10% of the costs on the surface of the floors, obtained by the method of digital printing.

Digital inkjet printers use a non-contact method of applying ink to a surface. However, laser printing is based on a contact method in which a laser beam projects an image onto an electrically charged rotating drum. Then, dry ink particles, commonly referred to as toner, are electrostatically captured by the charged areas of the drum. Printing ink contains small particles of dry plastic powder with soot or coloring agents. The material of thermosetting plastic acts as a binder. The drum prints the image on paper by direct contact or heating, which leads to the fusion of printing ink with paper by binding plastic powder to paper. Color laser printers use the CMYK color principle with color dry inks, typically colors such as cyan, magenta, yellow, and black, which are mixed to provide a high-quality color image.

Impact laser technology is not used for printing on flat panel surfaces, such as floor panel surfaces.

The foregoing description of the various known aspects represents their characterization by the applicant, and not the assumption that any information from the foregoing description is related to the prior art. Some of the above technologies are known and used individually, but not in all of the above combinations and not in all of the above methods.

In conclusion, it should be mentioned that digital printing is a very fast-moving method, but it cannot be used completely due to the high cost of printing ink. The costs are mainly due to the need to grind the colored pigments to well-defined very fine particles and disperse these particles throughout the carrier fluid. If digital images could be created using printing ink that does not contain colored pigments or colored substances, this would be a fundamental advantage.

To obtain the benefits associated with the ability to quickly adapt to creating high-resolution images, only digital application technology is used. However, other aspects of this technology are not fully utilized or developed, mainly related to the possibility of a very accurate application of a liquid substance in a non-contact manner.

It is known that the powder applied to a liquid substance can be used to create raised portions or images mainly on a paper substrate, and that the liquid substance can be applied digitally by inkjet printing.

No. 3,083,116 describes a powder for printing raised areas and a process for printing raised areas, which consists in spraying a powdery resin onto a newly printed sheet, removing excess powder that does not adhere to the wet ink, and applying heat to the powder adhered to the sheet, so that the powder particles will flow together and adhere to the sheet. The powder may contain phenolic resin.

US 3,446,184 describes a method for forming a sticky copy of an image. The toner powder is applied to the liquid formation, and part of the powder is fixed by the liquid coating, which leads to the formation of a visible image. The loose powder is removed, and the sheet is passed through a heating block, where the fixed powder is dissolved, forming a long-term image.

No. 4,312,268 describes a method by which water-based printing inks are digitally applied to a continuous web, and soluble, one-color powder material is applied to both the web and the printing ink. Part of the powder material binds to the liquid, and unbound powder material is removed from the fabric before heating the fabric to dry the liquid and to merge the powder material with the fabric by dissolving the powder. It is mentioned that the powder material may have a particle size in the range of 5 to 1000 microns and may have a dissolution temperature or fusion temperature in the range of 50 to 300 degrees Celsius. Powder material can be obtained by liquefying or dispersing, respectively, a dye or pigment in a resin or resin composition, followed by grinding, spray cooling, and the like. to turn the material into finely ground. Powder material can impart printing ink, which may contain phenolic resin, to abrasion resistance. The liquid material that is applied in jets can be clear and colorless water.

No. 6,387,457 describes a printing method using dry pigments. The binder material is applied to the surface of the substrate uniformly or in the form of a pattern. Dry pigment is applied to the binder material in the form of a pattern or evenly. The dry pigment material contains flakes of non-metallic material having a particle size of less than about 100 microns. The flakes are aligned in a direction parallel to the surface of the substrate.

EP 0403264 A2 describes a transfer method for forming a multi-color image on a drum that transfers this image to paper. The digital latent (latent) image is sequentially developed at the development station, where the colored powder is applied to the moving latent image and fixed, obtaining a visible long-term image. You can use several digital printheads that print with colorless fluids containing a mixture of water with polyhydric alcohols and their varieties such as ethylene glycol, glycerol, diethylene glycol and polyethylene glycol. Powder toner is applied across the surface of the paper, and a voltage is applied during development. Then the voltage sign is reversed to remove toner from the background zones. Fixation is achieved through conventional merging methods for copiers.

EP 0657309 A1 describes a multi-color transfer method involving the use of transfer paper bearing a pattern formed by inkjet printing and powder in a manner similar to the methods described above. This transfer method is intended for decorative ceramics.

WO 2011/107610 describes a method for creating an elevation or impression on a floor panel in order to avoid the use of expensive press plates. This method is the same as known methods for creating a raised print. This document describes a method of producing a floorboard by printing on a curable substrate to create an elevation on the panel. Elevation can be applied to the basic decorative pattern, which is directly printed or layered on the panel. The curable material may contain wear resistant particles. The curable material can be digitally printed on a panel by first printing with a liquid to give a predetermined pattern and then supplying an intermediate that may contain powder. The curable material may be curable by ultraviolet (UV) radiation or may be varnish.

Known methods are unsuitable for creating a high-quality multicolor image on a building panel, in particular, not on a floor panel, where pigments resistant to UV radiation should be used and where the image must be embedded in a wear-resistant surface. The possibility of using the known principles for creating images on the surface of the floor, which is pressed, is also unknown. In particular, it is unclear how to adapt the above principles for printing on floors similar to wood-fiber floors (WFF), where the powder, printing ink and application methods should be adapted to specific resins, materials and pressing parameters, which should determine the effective formation of wear-resistant, shock-resistant and stain-resistant quality multicolor surface.

OBJECTS AND SUMMARY OF THE INVENTION

The goal of at least some embodiments of the invention is to develop a method and equipment for the manufacture of a digitally printed building panel, preferably a floor panel, which can be manufactured in a more cost-effective manner without printing ink that contains a coloring material, for example, without colored pigments, the manipulation of which in a digital print head is difficult.

The above objectives are exemplary, and embodiments of the invention may provide for the solution of other or additional tasks.

The first aspect of the invention is a method of forming a digitally printed image using color pigments on the surface of a building panel, comprising the steps of:

dry colored pigments disperse on the surface;

bind part of the dry colored pigments to the surface; and

unbound dry color pigments are removed from the surface such that a digitally generated image is formed by the bonded dry color pigments.

In accordance with the first principle of the first aspect, a pattern or image can be formed by a digital coating head that only applies a binder to the surface. The pigments are scattered randomly over the pattern by means of an auxiliary device. A binder connects some pigments forming the same pattern as a binder, while others - unbound ones - remove the pigments.

This two-step process, in which pigments and a liquid binder are applied separately, can provide an image whose quality is comparable to that achieved by conventional digital printing technology, for example, comparable to a resolution of at least 300 DPI.

According to the second principle of the first aspect, the pigments can be scattered on the surface in the first step, and the digital print head, which only applies the binder to the scattered mixture, then forms a picture or image in a digital way. The digitally applied binder may contain water, which dissolves, for example, melamine-formaldehyde particles that can be mixed with pigments, preferably substantially homogeneously mixed with pigments. A binder connects some pigments that form the same pattern as the binder, and unbound pigments are removed.

In accordance with the third principle of the first aspect, the pigments can be scattered on the surface in the first stage, and a laser beam that binds some pigments to the surface by melting or curing a binder, which can be mixed with pigments or incorporated into the surface under the pigments, then forms a pattern or image digitally. A binder connects some pigments that form the same pattern as the binder, and unbound pigments are removed.

Dry colored pigments can be bonded to a binder on the surface of a building panel. The binder can be applied to the surface of the building panel separately.

Dry color pigments can be mixed with a binder.

The binder may be a powder, preferably a dry powder, or a liquid substance.

The binder may contain a thermosetting or thermoplastic resin. The surface of the building panel may comprise a thermosetting resin, preferably a melamine-formaldehyde resin.

The surface may be a paper layer, a foil, a wood layer or a wood-based layer, or a powder layer. The powder layer may contain a mixture containing wood-cellulosic or cellulosic particles, a binder and, optimally, wear-resistant particles, for example, aluminum oxide. The binder is preferably a thermosetting binder, such as a melamine formaldehyde resin.

The construction panel may have a surface of paper impregnated with resin, a thermoplastic film or foil, a powder layer containing wood-cellulosic or cellulosic particles and a binder. A building panel can be formed by applying heat and pressure.

A building panel may be a floor panel. The surface may be part of the floor panel.

The floor panel may comprise a mechanical interlock system for vertical and horizontal interlock.

A building panel may be a wall panel or a component of furniture. The surface may be part of a wall panel or furniture component.

Pigments can be removed with a stream of air.

The step of bonding said portion of the dry colored pigments to a surface may include applying a liquid substance through a digital coating head. The liquid substance can be applied to the surface before applying the dry colored pigments to the surface, or it can be applied to the surface after the dry colored pigments are applied to the surface.

The liquid substance may be water based.

The liquid substance can be exposed to UV radiation.

The liquid substance may be a water-based polyurethane, UV curable (UV-cured water-based polyurethane).

The liquid substance may contain a binder, such as a thermoset or thermoplastic binder.

The liquid substance can be applied using a piezo head for printing with printing inks.

The step of bonding said portion of the dry color pigments to the surface may include applying a laser beam to bind the dry color pigments to the surface.

The method may further include applying heat and pressure to the surface of the building panel. The surface of the building panel can be pressed after the digitally created image is formed by the associated colored pigments. The final bonding of dry colored pigments to the surface of the building panel can occur due to the application of heat and pressure to the surface of the building panel. For example, a binder that binds dry colored pigments to the surface of a building panel can be cured by applying heat and pressure to the surface of the building panel. A binder, for example a thermosetting resin, such as a melamine-formaldehyde resin that binds dry colored pigments to the surface of a building panel, can be cured simultaneously with a binder, for example a thermosetting resin, such as a melamine-formaldehyde resin, of the surface of a building panel. Curing can occur by applying heat and pressure to the surface of a building panel.

A second aspect of the invention is to develop digital imaging equipment on a building panel, the equipment comprising a digital coating head, a powder dispersion unit, and a powder removal system. The configuration of the digital coating head allows liquid to be applied to the surface of a building panel or a powder layer containing colored pigments and / or a binder on the surface of a building panel. The configuration of the powder dispersion assembly allows the application of a powder layer containing colored pigments on the surface of the building panel. The configuration of the liquid substance allows the binding of a part of the powder to the surface of the building panel, and the configuration of the powder removal unit removes unbound powder from the surface of the building panel. As a result, the associated color pigments form a digital image.

The powder may contain a thermosetting resin.

The liquid substance may be water based. The liquid substance can be exposed to UV radiation.

The surface of the building panel comprises a thermosetting resin, preferably a melamine-formaldehyde resin.

The equipment may further comprise a pressing unit adapted to apply heat and pressure to the surface of the building panel. The surface of the building panel can be pressed after the associated color pigments have formed a digital image.

The manufacturing method and equipment in accordance with embodiments of the invention makes it possible to quickly adapt and very cost-effectively obtain largely improved decorative patterns, since only digital equipment is used to create a pattern using a binder that does not have any color pigments.

Embodiments and details of various aspects may be combined with embodiments and details of other aspects. Mixing of colored pigments in a liquid binder is not ruled out, and this mixing, which may be necessary for a particular color combination, can be used, for example, for applying smaller amounts of pigments using a digital coating head.

Brief Description of the Drawings

The invention will be described in more detail below in connection with possible embodiments and with reference to the accompanying possible drawings, wherein:

FIG. 1a-d illustrate known methods for producing a printed and embossed surface;

FIG. 2a-d illustrate a first aspect of the invention;

FIG. 3a-d illustrate a second aspect of the invention;

FIG. 4a-d illustrate a third aspect of the invention;

FIG. 5a-h illustrate digital pigmentation in accordance with a first aspect of the invention;

FIG. 6a-c illustrate embodiments of the invention.

Detailed Description of Embodiments

In FIG. 2a-2d show an embodiment of the invention based on the first principle, according to which a binder BP pattern or image is digitally formed using a digital coating head that applies binder 11 in the form of a liquid substance. A digital print head or a digital head for printing with helmets, which is mainly used for supplying a liquid substance without any coloring substances and which is not intended for printing a color image, is hereinafter referred to as the "digital head for coating." Pigments 12 are scattered randomly by means of an auxiliary device on top of the binder BP pattern. A binder connects some pigments forming the same pattern as a binder, while others - unbound ones - remove the pigments.

This two-step process, in which pigments and a liquid binder are applied separately, can provide an image of the same quality as achieved by conventional digital printing technology. The method is suitable, in particular, in applications where significant amounts of pigments have to be applied to a large flat panel 1 in order to form an improved large image or decorative pattern. In contrast to known methods, a digital coating head is generally not used for printing any type of ink with colored pigments. This is a fundamental advantage since it is not necessary to manipulate expensive paints containing pigment dispersions with a digital coating head.

In FIG. 2a shows that by means of the digital coating head 30 shown in FIG. 2d, a binder BP pattern is formed on the surface 2 of the building panel 1. Surface 2 can be, for example, a paper layer, a stabilized powder layer, foil, or a base color after being applied to a material, preferably a core material based on wood or plastic. Binder 11 in this preferred embodiment is a water-based binder and contains mainly water, for example at least 50% water. Binder 11 may further comprise additives, such as a separating agent, surface tensioning agents, wetting agents, thickening agents, etc. A pigment layer 12 is applied, for example, by dispersing a dry powder over a wet binder BP pattern, as shown in FIG. 2b. The pigment layer may contain, for example, particles of melamine-formaldehyde powder, which dissolve when they come in contact with a water-based binder pattern. Dry pigments and melamine-formaldehyde powder that do not come into contact with the water-based binder pattern BP are removed, for example, by an air stream, and the remaining color pigments 12 form an imprint, as shown in FIG. 2c, which is substantially identical to the binder BP pattern.

The fingerprint P can be dried and stabilized, for example, by exposing it to infrared (IR) or UV radiation, which heat the wet melamine-formaldehyde resin and bind color pigments to surface 2 by drying the melamine-formaldehyde resin. Surface 2 can be coated with a second bonded pattern, and a second layer of pigments and melamine-formaldehyde powder can be applied to the surface on top of and next to the first print. You can create an improved decor with several colors.

The binder in this embodiment may contain wet melamine-formaldehyde resin and can be applied in two steps, in the first as a liquid substance, such as water, from a digital coating head 30, and in the second, as a powder from a dispersion unit 27. The powder can be mixed with dry colored pigments. This simplifies the function of the digital coating head, which only has to apply water droplets without binders and color pigments or with limited quantities of binders and color pigments.

A dry binder may be included in the powder and may be activated by a liquid substance applied by the coating head, as described above, or may be included in only the liquid substance supplied by the digital coating head.

This method, in which a liquid substance and powder are applied directly to a panel, is suitable for forming a digital image on a building panel. The method, including the following steps, is particularly suitable for forming an image on a floor surface having high impact resistance and wear resistance. A liquid substance compatible with thermosetting resins is applied, and this substance must have specific chemical properties such that defects do not occur during curing of the thermosetting resins. This can be achieved using a liquid substance that contains, for example, water and / or glycols. The substance should be applied to the surface of the building panel to avoid problems associated with the positioning of the print on the panel. The surface layer of the panel and / or the powder applied to the panel preferably includes thermosetting resins, such as melamine formaldehyde resins, and they can react with a liquid substance and bind the powder to the surface of the panel, so that unbound powder can be removed. The powder preferably contains UV-stable colored pigments. The advantages are that this combination of materials can be pressed or cured at high pressures in excess of 4 MPa (40 bar) and heated to temperatures in excess of 160 degrees Celsius. The surface and the digitally generated image can be cured to obtain a hard wear-resistant surface without the so-called mixing of the pigments during the pressing and heating steps, and the pigments can be embedded in the cured surface so that they can create a UV-resistant wear-resistant image similar to conventional laminated floors plastics.

A wide range of thermosetting and thermoplastic materials can be used as particles in dispersible powder or dispersions or liquid substances, in a binder applied by means of a digital coating head. Most of these materials can be obtained in the form of dry powder or dispersions of liquids.

As an alternative to thermosetting materials, such as melamine-formaldehyde resins, or thermoplastic materials, such as, for example, polyvinyl chloride (PVC) powder, for example, UV curable polyurethane can be used in powder form or as a dispersion.

A UV curable polyurethane material with a viscosity that is adapted to the digital head 30 for coating can be used. Water-based polyurethane dispersions are preferred as the liquid substance in the digital coating head, since they are not cured until they are exposed to UV radiation. Polyurethane dispersions are fully reacted polyurethane polyureas from small and discrete polymer particles, and such particles can be obtained with a size of about 0.01-5.0 microns, as a result of which they can be manipulated in a digital print head or other similar heads. They can have a solids content of 20-70%. Polyurethane dispersions can be mixed, for example, with acrylic emulsions and other emulsions to reduce costs.

The digital coating head 30, which is preferably a piezo head, preferably has some capacity to “shoot” droplets with a droplet volume of about 1-200 picoliters or more. The droplet volume can vary, and this can be used to change the color intensity to create a grayscale scale with the same basic colors.

Water-based adhesives such as water-soluble adhesives or water-dispersible adhesives may also be used.

In the powder for dispersion or as dispersions, other UV-curable materials can be used, such as acrylates of epoxy resin, urethane, polyester, polyether, amine-modified polyester acrylic and mixed acrylate oligomers.

In FIG. 2d shows a binder printing station of a binder printing equipment that can be used to create a digital fingerprint using a binder printing method. The digital coating head 30, which may be a piezo head, applies a binder BP pattern. To cover the width of the surface on which you want to print, you can position side by side several heads 30 for coating. A binder pattern is created digitally in the same way as with conventional digital printing. The colors are separated, and each coating unit 36 applies substantially the same substance that is used to bind one particular color at each coating step. The digital coating head is connected by a supply tube 32 to a container 31 that contains a binder or one binder component, preferably a water-based substance, which in this embodiment can be mainly distilled or deionized water. The digital coating heads are connected by digital data transfer cables 33 to a digital control unit 34 that controls droplet feed, conveyor speed 21, the operation of the powder application unit, and all other equipment used to bind and remove pigments.

The water droplets that serve as the binder 11 must be wet while they pass the dispersion station 27, which is a powder mixture, which in this preferred embodiment contains color pigments 12 and melamine-formaldehyde powder 13. The melamine-formaldehyde particles in the powder mixture that are in contact with a wet pattern of a water-based binder, BP dissolves, and the water-melamine-formaldehyde solution acts as a binder that connects part of the pigment-melamine-formaldehyde mixture with surface 2 of panel 1. When the powder mixture is moved under a preferably hot ultraviolet UV curing oven 23, which is preferably located after the digital coating unit 36 in the feed direction, almost instant bonding or curing can occur within a few seconds.

The powder removal system 28, which in this embodiment is based on air flow and vacuum, removes pigments and melamine-formaldehyde particles that are not associated with the binder BP pattern, provides an excellent color print P. This process step can be repeated, and a different color can be applied using a second a diffuser 27 that contains a different color of paint. Removed dried pigments and melamine-formaldehyde particles can be passed through a sieve or filter, and they can be recycled and reused several times.

Melamine formaldehyde or other binders can also be included in the surface layer 2 as a dry layer, for example, when a layer of paper impregnated with melamine formaldehyde resin or a stabilized powder layer is used as the base surface. The water-based binder pattern will dissolve part of this melamine-formaldehyde layer, and only pigments can be applied as a powder using the dispersion unit 27 and recycled. This method can also be used when all of the binder is part of a liquid substance applied by a digital coating head.

In addition to pigments and melamine-formaldehyde particles, the powder mixture may also contain wear-resistant particles, such as fine particles of alumina and fibers, preferably wood fibers, which preferably contain mixed transparent or translucent fibers. Such a mixture can be used to create a continuous imprint using pigments positioned vertically one above the other, with binder and wear-resistant particles being above and below the pigments. A water-based substance without any pigments can penetrate deeper into the powder mixture than pigments applied as a dispersion in conventional digital printing, and a very wear-resistant print can be obtained.

Several layers of prints can be placed one on top of the other, and this can be used to further increase the wear resistance and to create three-dimensional decorative effects.

Static electricity can be used to deposit and / or remove unbound powder particles. Air flows and vacuum, which cause blowing and / or suction of the particle, can be combined with brushes. In general, to remove pigments and unbound particles of the dispersed powder mixture, you can use - individually or in various combinations - all the "dry" and "wet" methods that are used to remove dust. However, "dry" and unstressed methods are preferred.

The controlled complete or partial removal of unbound pigments is essential for a high-quality print with a predefined decorative image. You can also use advanced removal systems that remove colored pigments, while a substantial portion of the transparent particles of melamine formaldehyde powder may remain on the surface. This can be achieved, for example, by two-stage scattering, in which the first layer contains only melamine-formaldehyde particles, which are connected to the surface before applying a binder, which is sprayed with water and which is dried using IR radiation, hot air, UV radiation and similar methods. This separate melamine-formaldehyde layer can in some applications replace, for example, pre-impregnated paper, and as surface layer 2, you can use only non-impregnated paper with or without a base color.

The moisture content of the surface layer must be precisely controlled to facilitate removal of unbound powder particles. A moisture content of less than 6% is preferred. The surface layer 2 can be dried, for example, by means of IR lamps or UV lamps or hot air before applying pigments. To densify surface 2 or the top of the bonded color pigments in order to create a sealing or separating layer that can prevent the color pigments from sticking to specific parts of the surface layer where the binder is not applied, water or special chemicals such as separating agents can be applied.

The print can be coated with transparent protective layers, for example, paper-based coatings or powder-based coatings containing alumina and melamine-formaldehyde resins, or with a UV-curable coating that can be applied by rollers or digitally, for example, by means of piezo coating heads.

In FIG. 3a-3d illustrate an embodiment of the invention based on the second principle, according to which the pigments 12 are scattered on the surface 2 in the first step and then digitally form a pattern or image using a digital coating head that only applies a binder pattern to the scattered mixture BP The digitally applied binder may contain water, which dissolves, for example, melamine-formaldehyde particles 13 mixed with pigments 12 or applied under pigments. A binder connects some pigments that form the same pattern as the binder BP pattern, while others - unbound - pigments are removed. In FIG. 3a shows a substantially homogeneous mixture of melamine-formaldehyde powder 13 and pigments 12 dispersed on surface 2. FIG. 3b shows a digitally applied drawing of a binder BP after application to the mixture. In FIG. 3c shows that all unbound pigments have been removed and, in this embodiment, also melamine formaldehyde particles 13. FIG. 3d shows a binder printing station comprising a dispersion unit 27, a digital coating unit 36, a UV oven 23, and a powder removal system 28 based on air and vacuum flow.

The combination of the first and second principles is possible. The binder pattern can be applied before and after applying the pigment mixture, and this can be used to create a continuous print with a greater vertical length and increased wear resistance.

In FIG. 4a-4c, an embodiment of the invention is shown, which is based on the third principle, according to which the pigments 12 are scattered on the surface 2 at the first stage, and then digitally form a binder BP or image using a laser beam 29 melting or curing the binder, which can be mixed with pigments 12 or be a part of surface 2. When removing unbound pigments, a digitally generated P print is obtained.

In FIG. 4d shows a binder printing station comprising a scattering unit 27, a laser 29 and a powder removal system 28 based on air and vacuum flow. The laser can be replaced with heating lamps, which can be used to create images that can include quite large areas of the same color, as in some stone-like designs. Even a conventional laser system based on the above-described impact method can be used alone or in combination with the above-described printing methods with a binder for applying a digital print partially or completely to the floor panel.

All of the above principles can be combined partially or completely, and the production line can contain several digital printing stations as a binder in accordance with the first, second or third principles.

In FIG. 5a-5h show the use of different colors in accordance with the first principle. The first binder 11a, which in this embodiment is essentially water, is applied with a digital piezo head to surface 2, which may be a stabilized powder layer or paper, as shown in FIG. 5a. On the surface 2 and on the binder 11a, a first layer of powder is applied containing colored pigments 12a and melamine-formaldehyde particles 13a. Melamine formaldehyde particles 13a that are in contact with wet drops of water will dissolve. The first UV oven 23a dries the wet melamine-formaldehyde particles and bonds the pigments to the surface, as shown in FIG. 5c, rather than bonded melamine-formaldehyde particles and pigment particles are removed so that a pigment image 12a is obtained that corresponds to the applied binder 11a. In FIG. 5e-5h show that the same application can be repeated with a different color pigment 12b mixed with melamine-formaldehyde particles 13b and a new binder 11b, so that two color images of two types of color pigments 12a, 12b are obtained, as shown in FIG. 5h.

In FIG. 6a shows an embodiment in which digital binder printing equipment comprising a digital coating unit 36, a diffusing unit 27, a UV curing unit 23 and a vacuum powder removal system 28 is combined with a conventional inkjet printing device 35. The method for printing a binder may include this combination to create the main part of the digital image, and some parts of the finished print can be created using an inkjet printer. This can significantly reduce costs, for example, for printing ink, since for 90% of the pigments that are needed to create a fully printed decor or pattern, for example, a cost-effective method of printing with a binder is used, in which you do not have to manipulate the pigments with a digital coating head.

In FIG. 6b shows digital binder printing equipment, where pigments 12 and melamine-formaldehyde powder 13 are applied by a dispersion unit 27, preferably containing an embossed roller 22 and an oscillating brush 42. Unbound pigments and melamine-formaldehyde particles are removed by a powder removal system 28 that recirculates the mixture 12, 13 in block 27 dispersion. Through the flow of air, it is possible to create a cloud of pigment - melamine-formaldehyde dust, and only pigments and melamine-formaldehyde powder will contact the surface 2, which come into contact with the wet binder 11.

In FIG. 6c shows that the method is particularly suitable for applying a digital fingerprint of a binder to a floor panel 1 with a paper or powder based surface 2, a core 3, a balancing layer 4 and with a mechanical locking system comprising a strip 6 with a blocking element 8 on one edge, which interacts with the locking groove 14 in the adjacent edge to horizontally lock the neighboring edges, and the tongue 10 on one edge, which interacts with the groove 9 of the tongue in the other edge to vertically lock the panels. Such floor panels have generally improved “wood” or “stone” decors, which require large amounts of different colored pigments, and decor that has to be accurately positioned relative to the embossed structures and edges of the panels with a mechanical locking system.

In all embodiments, the surface of the building panel may comprise a thermosetting resin, for example a melamine-formaldehyde resin. A building panel can be formed by applying heat and pressure, preferably after a digitally generated image is formed by bonded color pigments. In one embodiment, a binder mixed with dry color pigments is cured simultaneously as a binder in the surface of a building panel, preferably by applying heat and pressure.

All of the above methods can be combined - partially or completely.

Example

A 300 g / m 2 powder mixture containing wood fibers, melamine-formaldehyde particles, brown colored pigments, and alumina particles such as corundum was applied by dispersion equipment to an 8 mm thick HDF core. The mixture was sprayed with deionized water and dried by means of a UV oven so that a solid surface was obtained on the basis of a stabilized powder with a brown base color. A panel with a stabilized powder-based surface was placed on a conveyor and moved under a digital piezo head for coating, which applied water droplets to a stabilized surface and which printed a transparent pattern of wood fibers on that surface. The melamine-formaldehyde particles under the transparent pattern were dissolved when the digital piezo head for coating applied droplets of water. In the second stage, black pigments were scattered over the entire surface and the transparent pattern. After that, the panel was moved by means of a conveyor under the UV oven. The melamine-formaldehyde particles in the transparent pattern were again dried, and the pigments above the transparent pattern were bonded to the surface. After that, the panel was moved under a vacuum suction tube, through which all unbound pigments and melamine-formaldehyde particles were removed. The result was a pattern of wood fibers that had a brown base color and a black structure of wood fibers. A protective layer containing melamine-formaldehyde particles and aluminum oxide particles was scattered over the entire surface. Water was sprayed onto this layer and dried under a UV oven. A panel with a fingerprint and a protective layer was then pressed for 20 seconds at a temperature of 170 degrees Celsius and a pressure of 4 MPa (40 bar), and the powder-based surface with the structure of wood fibers and the protective layer were cured, obtaining a solid wear-resistant surface with a high-quality print.

Claims (31)

1. The method of forming a digitally printed image (P) using colored pigments (12) on the surface (2) of the building panel (1), which includes the steps in which:
dry colored pigments (12) are scattered on the surface (2);
bind part of the dry colored pigments to the surface (2);
unbound dry color pigments are removed from the surface in such a way that a digitally created image (P) is formed by the bonded dry color pigments (12); and
apply heat and pressure to the surface (2) of the building panel (1),
wherein the step of bonding said portion of the dry colored pigments to the surface (2) includes applying a liquid substance (11) by means of a digital head (30) for coating.
2. The method according to p. 1, in which dry colored pigments (12) are associated with a binder on the surface (2) of the building panel (1).
3. The method according to claim 1, in which dry colored pigments (12) are mixed with a binder.
4. The method according to p. 2 or 3, in which the binder contains a thermosetting resin.
5. The method according to p. 2 or 3, in which the binder contains a thermoplastic resin.
6. The method according to p. 2 or 3, in which the binder is a powder.
7. The method according to claim 1 or 2, in which the surface (2) of the building panel (1) contains a thermosetting resin.
8. The method according to claim 1 or 2, in which the surface (2) of the building panel (1) is a layer of paper or foil.
9. The method according to claim 1 or 2, in which the surface (2) of the building panel (1) contains a layer of powder.
10. The method of claim 1 or 2, wherein the building panel is a floor panel (1).
11. The method according to claim 10, in which the floor panel (1) comprises a mechanical locking system (6, 8, 9, 10, 14) for vertical and horizontal locking.
12. The method according to claim 1 or 2, in which the building panel is a wall panel or a component (1) of furniture.
13. The method according to p. 1 or 2, in which dry colored pigments (12) are removed by a stream of air.
14. The method according to claim 1 or 2, in which the liquid substance (11) is a water-based substance.
15. The method according to p. 1 or 2, further providing for the effect of UV radiation (23) on the liquid substance (11).
16. The method according to p. 15, in which the liquid substance (11) is a UV-based water-based polyurethane.
17. The method according to claim 1 or 2, in which the liquid substance (11) contains a thermosetting binder.
18. The method according to p. 1 or 2, in which the liquid substance is applied using a piezo head for printing with printing inks.
19. A method according to claim 1 or 2, wherein the step of bonding said portion of the dry color pigments to the surface (2) includes supplying a laser beam (29) to bind the dry color pigments to the surface.
20. Equipment for providing a digital image (P) on a building panel (1), this equipment comprising a digital head (30) for coating, a powder dispersion unit (27) and a powder removal system (28), characterized in that:
the digital head (30) for coating is arranged to apply liquid substance (11) to the panel, the powder dispersion unit (27) is configured to deposit a layer of powder containing colored pigments (12) on the surface of the building panel, while the liquid substance is made with the possibility of binding part of the powder to the panel, and the powder removal unit (28) is configured to remove unbound powder from the panel (1),
the equipment further comprises a pressing unit configured to apply heat and pressure to the panel (1).
21. The equipment according to claim 20, in which the powder contains a thermosetting resin.
22. Equipment according to claim 20 or 21, in which the liquid substance (11) is a water-based substance.
23. Equipment according to claim 20 or 21, in which the liquid substance (11) is exposed to UV radiation.
24. Equipment according to claim 20 or 21, wherein the surface layer (2) of the building panel comprises a thermosetting resin.
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WO2014017972A1 (en) 2014-01-30
KR20150046784A (en) 2015-04-30
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BR112015001612A2 (en) 2017-07-04

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