US20150290968A1 - Decorative wpc panel comprising a low-porous profiled edge and method for producing the same - Google Patents
Decorative wpc panel comprising a low-porous profiled edge and method for producing the same Download PDFInfo
- Publication number
- US20150290968A1 US20150290968A1 US14/669,357 US201514669357A US2015290968A1 US 20150290968 A1 US20150290968 A1 US 20150290968A1 US 201514669357 A US201514669357 A US 201514669357A US 2015290968 A1 US2015290968 A1 US 2015290968A1
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- United States
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- carrier
- plate
- decor
- wpc
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Images
Classifications
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- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2793/00—Shaping techniques involving a cutting or machining operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2795/00—Printing on articles made from plastics or substances in a plastic state
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/001—Mechanical features of panels
- E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/005—Appearance of panels
- E04C2002/008—Panels with the appearance of a natural stone wall
Definitions
- the present invention relates to a decorative WPC panel comprising a low-porous profiled edge and a method for producing in particular direct printed decorative panels comprising a low-porous profiled edge.
- Decorative plates or decorative panels are known per se and used in a variety of ways for covering walls, ceilings or floors. They normally consist of a carrier or core of a solid material, for example a wood-based material, which is provided on at least one side with a decorative layer and a top layer and optionally with further layers, such as a wearing layer.
- the decorative layer is usually a printed paper which is impregnated with a resin.
- the top layer and the remaining layers often comprise a resin.
- the carrier of such a decorative panel consists usually of wood or a wood-based material such as a MDF or HDF board or an OSB board, onto which an appropriate decoration, e.g. by applying a decorative sheet of paper, and usually further top layers are applied.
- an appropriate decoration e.g. by applying a decorative sheet of paper, and usually further top layers are applied.
- WPC wood-plastic-composite plastic or wood polymer composite
- the plate-shaped carriers are usually processed as large format plates, which are divided in the course of the processing into a plurality of panels of a desired size. Then in addition the panels are generally provided with a functional profiling such as a tongue and groove profile or a locking profile at at least one edge by means of which the panels can be connected during the assembly in order to provide a contiguous surface.
- a functional profiling such as a tongue and groove profile or a locking profile at at least one edge by means of which the panels can be connected during the assembly in order to provide a contiguous surface.
- one disadvantage in cutting or profiling of the plate-shaped carriers is that at the cutting surfaces wood fibers of the WPC material may be exposed, which may swell when exposed to moisture and thus can lead to a damage of the panel.
- a decorative panel comprising a plate-shaped carrier made of a wood plastic composite (WPC) material, wherein the plate-shaped carrier in at least one edge region has a profile and/or a cutting edge, and wherein the profile and/or cutting edge comprises a substantially sealed surface.
- WPC wood plastic composite
- the object is achieved by a method for producing a decorative panel, comprising the steps of forming a profile and/or a cutting edge in at least one edge of the plate-shaped carrier made from a WPC material, and subjecting a surface of the introduced profile and/or cutting edge to a thermal treatment to at least partially melt the WPC material in the region of the profile and the surface is sealed.
- FIG. 1 is a schematic illustration of a panel of the invention.
- the invention thus proposes a decorative panel comprising a plate-shaped carrier made of a wood plastic composite (WPC) material, wherein the plate-shaped carrier has in at least one edge region a profile and/or a cutting edge, characterized in that the profile and/or the cutting edge has a substantially sealed surface.
- FIG. 1 shows the decorative panel 100 comprising the plate-shaped carrier 110 made of the WPC material. Decor 120 is applied to the carrier. In at least one edge region 130 the plate-shaped carrier has a profile and/or a cutting edge. The profile and/or cutting edge comprises a substantially sealed surface 150 , as shown at detail 200 .
- WPC wood plastic composite
- a sealed surface in the sense of the invention is a surface which essentially comprises no open wood fibers at the direct surface, rather the surface substantially consists of a closed layer of plastic. This does not preclude that wood fibers are disposed on the surface, but they are surrounded by plastic in such a way that moisture cannot penetrate into the wood fibers.
- decorated wall or floor panel or “decorative panel” in the sense of the invention means in particular wall, ceiling or floor panels comprising a decor simulating a decoration template applied onto a carrier plate.
- Decorative panels are used in a variety of ways both in the field of interior design of rooms and for decorative cladding of buildings, for example in exhibition stand construction.
- One of the most common uses of decorative panels is their use as a floor covering.
- the decorative panels often comprise a decor intended to replicate a natural material.
- replicated natural materials or decoration templates are wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or even exotic woods such as Panga Panga, mahogany, bamboo and bubinga.
- wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or even exotic woods such as Panga Panga, mahogany, bamboo and bubinga.
- exotic woods such as Panga Panga, mahogany, bamboo and bubinga.
- natural materials such as stone surfaces or ceramic surfaces are replicated.
- a “decoration template” in the sense of the present invention in particular means such an original natural material or at least a surface of such a material which is to be imitated or replicated by the decor.
- a “pourable” material in particular means a material which can be applied onto a base by a pouring or scattering process.
- the material may be provided as a fluid or in particular as a pourable solid.
- a “granulate material” or “granular material” means a solid or a head of a solid comprising or consisting of a plurality of solid particles, such as grains or beads.
- grainy or powdery materials can be mentioned.
- a “carrier” in particular can be understood as a layer serving as a core or as a base layer in a finished panel, which in particular includes a material comprising a plastic and wood fibers and/or wood particles.
- the carrier can already provide or contribute to a suitable stability for the panel.
- a “web-like carrier” can be understood as a carrier which, for example, during its manufacturing process has a web-like shape and thus a length which is substantially greater than its thickness or width, wherein its length may be greater than 15 meters.
- the term “plate-shaped carrier” in the sense of the present invention can be understood as a carrier which is formed by separation from the web-like carrier and is formed in the shape of a plate.
- the plate-shaped carrier can already define the shape and/or size of the panel to be produced.
- the plate-shaped carrier can also be provided as a large plate.
- a large plate in the sense of the invention in particular is a carrier whose dimensions several times exceed the dimensions of the final decorative panels, and which is cut during the course of the manufacturing process into a corresponding plurality of decorative panels, for example by sawing, laser or water jet cutting.
- the large plate may correspond to the web-like carrier.
- Wood-based materials in the sense of the invention in particular are wood-based materials such as wood polymer materials (Wood Plastic Composite, WPC).
- fiber materials means materials such as paper and non-woven fabrics on the basis of plant, animal, mineral or even synthetic fibers as well as cardboards.
- animal fiber materials are keratin-based materials such as wool or horsehair.
- mineral fiber materials are mineral wool or glass wool.
- a carrier material based on a plastic or a wood plastic composite material can be provided.
- the carrier plate can be formed from a thermoplastic, elastomeric or duroplastic plastic material.
- recycling materials from said materials can be used in the context of the method according to the invention.
- preferred plate materials may be in particular thermoplastic plastic materials, such as polyvinyl chloride, polyolefins (for example polyethylene (PE), polypropylene (PP), polyamide (PA)), polyurethane (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyether ether ketone (PEEK) or mixtures or copolymerizates thereof.
- plasticizers may be provided which may be present in a range of ⁇ 0 wt. % to ⁇ 20 wt.
- a suitable plasticizer for example, is a plasticizer available under the trade name “Dinsch” from BASF company.
- copolymers such as acrylates or methacrylates can be used.
- thermoplastic plastic materials offer the advantage that the products made from them can easily be recycled. It is also possible to use recycling materials from other sources. This enables a further reduction of the manufacturing costs.
- Such carriers are very elastic or springy, which allows a comfortable feeling when walking on them and also a suppression of noises occurring during walking on them compared to conventional materials, thus, an improved impact sound can be realized.
- the abovementioned carriers offer the advantage of a good water resistance, because they have a degree of swelling of 1% or less. This in a surprising way besides pure plastic carriers also applies to WPC materials, as will be explained in detail below.
- the carrier material can comprise or consist of wood polymer materials (Wood Plastic Composite, WPC).
- wood and a polymer may be suitable, which can be present in a ratio of 40/60 to 70/30, such as 50/50.
- polymeric components polypropylene, polyethylene or a copolymer of the two abovementioned materials can be used.
- Such materials offer the advantage that they can be formed into a carrier in the above-described process already at low temperatures, such as in a range of 180° C. to 200° C., so that a particularly effective process control, such as with exemplary line speeds in a range of 6 m/min, is possible.
- a WPC product with a 50/50 proportion of wood and polymer components with an exemplary product thickness of 4.1 mm is possible, which may allow for a particularly effective manufacturing process.
- WPC materials can include, for example, stabilizers and/or other additives which preferably may be present in the plastic portion.
- the carrier material comprises or consists of a PVC-based material. Even such materials can be used in a particularly advantageous manner for high quality panels that can easily be used even in wet rooms. Furthermore, also PVC-based carrier materials may be useful for a particularly effective manufacturing process, since here line speeds of 8 m/min for an exemplary product thickness of 4.1 mm may be possible, which could allow for a particularly effective manufacturing process. Moreover, also such carriers have an advantageous elasticity and water tolerance, which can lead to the above-mentioned advantages.
- mineral fillers may be advantageous.
- Particularly suitable are talc or calcium carbonate (chalk), aluminum oxide, silicagel, quartz powder, wood flour and gypsum.
- talc or calcium carbonate (chalk) aluminum oxide
- silicagel silicagel
- quartz powder silicagel
- wood flour wood flour
- gypsum talc or calcium carbonate
- chalk may be provided in a range of ⁇ 30 wt. % to ⁇ 70 wt. %, wherein the fillers, in particular chalk can improve the slip of the carrier. They also can be colored in a known manner.
- the plate material comprises a flame retardant.
- the carrier material consists of a mixture of a PE/PP block copolymer with wood.
- the proportion of the PE/PP block copolymer and the proportion of wood can range between ⁇ 45 wt. % and ⁇ 55 wt. %.
- the carrier material can comprise between ⁇ 0 wt. % and ⁇ 10 wt. % of other additives such as flow agents, heat stabilizers or UV stabilizers.
- the particle size of the wood is between >0 ⁇ m and ⁇ 600 ⁇ m with a preferred particle size distribution of D 50 ⁇ 400 ⁇ m.
- the carrier material may comprise wood with a particle size distribution of D 10 ⁇ 400 ⁇ m.
- the particle size distribution is based on the volumetric diameter and refers to the volume of the particles.
- the carrier material is provided as granular or pelletized pre-extruded mixture of a PE/PP block copolymer with wood particles with the specified particle size distribution.
- the granules and/or pellets can preferably have a particle size in the range of ⁇ 400 ⁇ m to ⁇ 10 mm, preferably ⁇ 600 ⁇ m to ⁇ 10 mm, in particular 800 ⁇ m to 10 mm.
- the carrier material consists of a mixture of a PE/PP polymer blend with wood.
- the proportion of PE/PP polymer blend as well as the proportion of wood can range between ⁇ 45 wt. % and ⁇ 55 wt. %.
- the carrier material can comprise between ⁇ 0 wt. % and ⁇ 10 wt. % of other additives such as flow agents, heat stabilizers or UV stabilizers.
- the particle size of the wood is between >0 ⁇ m and 600 ⁇ m with a preferred particle size distribution of D 50 ⁇ 400 ⁇ m.
- the carrier material may comprise wood with a particle size distribution of D 10 ⁇ 400 ⁇ m.
- the particle size distribution is based on the volumetric diameter and refers to the volume of the particles.
- the carrier material is provided as a granular or pelletized preextruded mixture of a PE/PP polymer blend with wood particles with the specified particle size distribution.
- the granules and/or pellets can preferably have a particle size in the range of ⁇ 400 ⁇ m to ⁇ 10 mm, preferably ⁇ 600 ⁇ m to ⁇ 10 mm, in particular ⁇ 800 ⁇ m to ⁇ 10 mm.
- the carrier material consists of a mixture of a PP homopolymer with wood.
- the proportion of the PP homopolymer and the proportion of wood can range between ⁇ 45 wt. % and ⁇ 55 wt. %.
- the carrier material can comprise between ⁇ 0 wt. % and ⁇ 10 wt. % of other additives, such as flow agents, heat stabilizers or UV stabilizers.
- the particle size of the wood is between >0 ⁇ m and ⁇ 600 ⁇ m with a preferred particle size distribution of D 50 ⁇ 400 ⁇ m.
- the carrier material can comprise wood with a particle size distribution of D 10 ⁇ 400 ⁇ m.
- the particle size distribution is based on the volumetric diameter and refers to the volume of the particles.
- the carrier material is provided as a granular or pelletized pre-extruded mixture of a PP homopolymer with wood particles of the specified particle size distribution.
- the granules and/or pellets can preferably have a particle size in the range of ⁇ 400 ⁇ m to ⁇ 10 mm, preferably ⁇ 600 ⁇ m to ⁇ 10 mm, in particular ⁇ 800 ⁇ m to ⁇ 10 mm.
- the carrier material consists of a mixture of a PVC polymer with chalk.
- the proportion of the PVC polymer and the proportion of chalk can range between ⁇ 45 wt. % and ⁇ 55 wt. %.
- the carrier material can comprise between ⁇ 0 wt. % and ⁇ 10 wt. % of other additives, such as flow agents, heat stabilizers or UV stabilizers.
- the particle size of the chalk is between >0 ⁇ m and ⁇ 600 ⁇ m with a preferred particle size distribution of D 50 ⁇ 400 ⁇ m.
- the carrier material may comprise chalk with a particle size distribution of D 10 ⁇ 400 ⁇ m.
- the particle size distribution is based on the volumetric diameter and refers to the volume of the particles.
- the carrier material is provided as a granular or pelletized pre-extruded mixture of a PVC polymer with chalk with the specified particle size distribution.
- the granules and/or pellets can preferably have a particle size in the range of 400 ⁇ m to 10 mm, preferably 600 ⁇ m to 10 mm, in particular 800 ⁇ m to 10 mm.
- the carrier material consists of a mixture of PVC polymer with wood.
- the proportion of the PVC polymer and the proportion of the wood can range between 45 wt. % and 55 wt. %.
- the carrier material can comprise between 0 wt. % and 0 wt. % of other additives, such as flow agents, heat stabilizers or UV stabilizers.
- the particle size of the wood is between >0 ⁇ m and ⁇ 600 ⁇ m with a preferred particle size distribution of D 50 ⁇ 400 ⁇ m.
- the carrier material can comprise wood with a particle size distribution of D 10 ⁇ 400 ⁇ m. The particle size distribution is based on the volumetric diameter and refers to the volume of the particles.
- the carrier material is provided as granular or pelletized pre-extruded mixture of a PVC polymer with wood particles of the specified particle size distribution.
- the granules and/or pellets can preferably have a particle size in the range of ⁇ 400 ⁇ m to ⁇ 10 mm, preferably ⁇ 600 ⁇ m to ⁇ 10 mm, in particular ⁇ 800 ⁇ m to ⁇ 10 mm.
- D 50 or D 10 values can be determined, according to which 50% and 10%, respectively, of the measured particles are smaller than the specified value.
- the carrier material may comprise hollow microspheres.
- This kind of additives can in particular cause that the density of the carrier and thus of the produced panel can be significantly reduced, such that a particularly simple and cost-effective transportation and also a very comfortable laying can be guaranteed.
- a stability of the produced panel can be ensured which is not significantly reduced compared to a material without hollow microspheres.
- hollow microspheres can be understood in particular as structures, which have a hollow basis body and a size or a maximum diameter in the micrometer range.
- usable hollow spheres may have a diameter in the range of ⁇ 5 ⁇ m to ⁇ 100 ⁇ m, such as ⁇ 20 ⁇ m to ⁇ 50 ⁇ m.
- a material of the hollow microspheres basically any material comes into consideration, such as glass or ceramic.
- the weight plastics, such as the plastics used in the carrier material, such as PVC, PE or PP can be advantageous, wherein these optionally can be prevented from deforming during the manufacturing process by suitable additives.
- the decorative panel comprises a decor which is applied onto the plate-shaped carrier by means of direct printing.
- direct printing means applying a decor directly onto the carrier of a panel or onto an unprinted fiber material layer or decor base applied onto the carrier.
- different printing techniques such as flexographic printing, offset printing or screen printing can be used.
- digital printing techniques for example, inkjet or laser printing processes can be used.
- the decor in order to imitate or replicate a decoration template in a particularly detailed and highly accurate manner in a three-dimensional form, the decor can be applied identically to the template.
- the three-dimensional decor data can be provided by three-dimensionally scanning the decoration template by means of electromagnetic radiation such as by a three-dimensional scanner (3D scanner).
- a plurality of decor layers with at least partially different surface application amounts can successively be applied on the basis of provided three-dimensional decor data.
- the decorative layers may be formed of a particularly radiation curable paint and/or ink.
- a UV-curable paint or ink can be used.
- a particular detailed and matching replica of the decoration template can be obtained.
- On the one side a highly accurate synchronous pore can be achieved in this way without providing further measures.
- a synchronous pore can in particular be a pore or another structure, which is spatially located exactly there where it is displayed visually by a haptic texture matching with the optical decor features. In this embodiment this is essentially automatically the case, because the structural design is created by the paint or ink.
- decoration templates such as wood-based materials, often comprise a variation of the color impression not only along their width or length but also along their depth.
- radiation curable paint in the sense of the invention means a composition which includes a binder and/or a filler as well as color pigments and which induced by electromagnetic radiation of a suitable wavelength, such as UV radiation or electron beams, can be at least partially polymerized.
- radiation curable ink in the sense of the invention means a composition essentially free of fillers and comprising color pigments, which induced by electromagnetic radiation of a suitable wavelength, such as UV radiation or electron beams, can be at least partially polymerized.
- the decorative layers each can be applied in a thickness in the range of ⁇ 5 ⁇ m to ⁇ 10 ⁇ m.
- a positive image with respect to the color and/or texture it can also be provided to apply a corresponding negative image of the decoration template.
- the color impression e.g. of a texture can be inverted, so that with respect to the color and in particular with respect to lighter and darker areas a negative is created.
- a similar effect, in addition to the color impression, is possible for the applied texture, too, such that also with respect to the structural design a negative can be realized.
- Such effects, too can be integrated into a manufacturing process based on digital three-dimensional data without any problems and without lead-time or retrofitting.
- the invention is also directed to a method for producing a decorative panel comprising the steps of:
- the wood fibers and/or particles exposed by processing the decorative panel or the carrier plate can be sealed by a thermal treatment which effects a melting of the surface such that the swelling behavior with respect to the impact by moisture can be reduced significantly.
- swelling of the profiled edges and/or cutting surfaces and the concomitant damage of the decorative panel in the case of impact by moisture can be avoided.
- the WPC material is merely molten near-surface.
- Near-surface means in the sense of the invention up to a depth of ⁇ 3 mm, preferably ⁇ 2 mm, more preferably ⁇ 1 mm and in particular ⁇ 0,8 mm.
- the method it is provided that after profiling or sawing the decorative panels or the plate-shaped carrier melting of the WPC material in the near-surface region is implemented in a process step downstream of the profiling and/or sawing process.
- a temperature controlled melting head may be provided which with respect to its profile corresponds to the profile or cut introduced in the edge and is guided over the surfaces of the profile or cutting surfaces, wherein the WPC material melts near-surface.
- the melting head is preferably maximally heated up to a temperature ⁇ 30° C. above the melting temperature of the WPC material.
- the introduction of the profile and/or the cutting edge is implemented by means of a cutting or machining process such as by milling or sawing.
- the melting of the WPC material is implemented by heating the cutting tool used for profiling and/or cutting of the at least one edge of the plate-shaped carrier by machining to a temperature greater than or equal to the melting temperature and lower than the decomposition temperature of the WPC material.
- the cutting tool is maximally temperature controlled to a temperature ⁇ 30° C. above the melting temperature of the WPC material.
- the temperature control of the cutting or machining tool is implemented by a heating and/or cooling device.
- the temperature of the cutting or machining tool is monitored contact-free, for example by means of an infrared temperature sensor or an infrared thermometer. Then the temperature control of the tool can preferably be carried out as a function of the data collected in the course this monitoring.
- At least a part of the temperature control of the cutting and/or machining tool is implemented by use of the heat produced by the cutting and/or machining process itself. This heat is caused by the friction between the tool and the material.
- the processing speed in particular the rotation speed of the tool and the relative velocity between the decorative panel/carrier plate and the cutting or milling head is adjusted such that the heat of the tool generated during the machining process occurs in a temperature range greater than or equal to the melting temperature of the WPC material and lower than the decomposition temperature of the WPC material.
- At least the profiled region of the edge of the plate-shaped carrier and/or the cutting surface is cooled down to a temperature below the melting temperature after melting of the WPC material and sealing the surface.
- This cooling according to the invention can be carried out by an air flow directed onto the corresponding surface.
- the air flow is cooled and thus has a temperature below the ambient temperature of the machining site.
- a temperature controlled cooling head can be used which with respect to its profile corresponds to the profile or cut introduced into the edge and is guided over the surfaces of the profile or cutting surfaces, wherein the WPC material is cooled down to a temperature below the melting temperature of the WPC material.
- the cooling of the WPC material molten near-surface is implemented within a period of ⁇ 60 s, preferably ⁇ 45 s, in particular ⁇ 30 s. In this way it can be ensured that no subsequent unwanted deformation of the profile is caused.
- the method may comprise further process steps to provide the carrier with a decor and to coat the decor with a protective layer.
- a pretreatment of the carrier for electrostatic discharge or specific charge before applying a decorative image using a direct printing method can be implemented.
- This in particular can serve to prevent the occurrence of blurring in the course of the decor application.
- This is particularly suitable for printing processes for applying the decorative layers, because the electrostatic charge which builds up in the carriers to be printed in the course of the production process results in a deflection of paint or ink droplets on their way from the print head to the surface to be printed. The thus induced inaccuracy of the paint application leads to a perceivable blurring of the printed image.
- the means for discharging electrostatic charges may at least comprise a roller, a brush or a lip of a conductive material having a conductivity ⁇ 1 ⁇ 10 3 Sm ⁇ 1 , which electrically conductive contacts the carrier at least in the region of the printing mechanism and which is connected to an electrical ground potential.
- the electrical ground potential may be provided, for example, by a grounding.
- a means for discharging electrostatic charges may be a means for producing a corona discharge.
- a decor base or print base is applied to at least a portion of the carrier.
- a primer particularly suited for printing processes can be applied as a decor base, for example in a thickness of 10 ⁇ m to 60 ⁇ m.
- a primer a liquid radiation curable mixture based on a urethane or urethane acrylate, optionally with one or more of a photo initiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, radical scavengers, leveling agent, antifoam or preservative, pigment, and/or a dye can be used.
- the urethane acrylate may be included in the primer composition in the form of reactive oligomers or prepolymers.
- reactive oligomer and “prepolymer” in the sense of the invention is a compound comprising urethane acrylate units which is able to react radiation-induced, optionally with addition of a reactive binder or a reactive diluent, into urethane polymer or urethane acrylate polymer.
- urethane acrylates in the sense of the invention are compounds which substantially are composed of one or more aliphatic structural elements and urethane groups.
- Aliphatic structural elements comprise both alkylene groups, preferably comprising 4 to 10 carbon (C) atoms and cycloalkylene groups preferably comprising 6 to 20 carbon atoms. Both the alkylene and the cycloalkylene groups may be mono- or polysubstituted with C 1 -C 4 alkyl, in particular methyl and include one or more non-adjacent oxygen atoms.
- the aliphatic structural elements are optionally linked to each other via quaternary or tertiary carbon atoms, via urea groups, biuret, uretdione, allophanate, cyanurate, urethane, ester or amide groups or via ether oxygen or amine nitrogen.
- urethane acrylates in the sense of the invention can also include ethylenically unsaturated structural elements. These preferably include vinyl or allyl groups, which may be substituted with C 1 -C 4 alkyl, in particular methyl and which, in particular, are derived from ⁇ , ⁇ -ethylenically unsaturated carboxylic acids and their amides. Particularly preferred ethylenically unsaturated structural units are acryloyl and methacryloyl groups such as acrylamido and methacrylamido and in particular acryloxy and methacryloxy.
- Radiation-curable in the sense of the invention means that the primer composition induced by electromagnetic radiation of a suitable wavelength, such as ultraviolet radiation or electron beams, can be at least partially polymerized.
- urethane acrylates allow in a particularly advantageous manner an application of the decor immediately subsequent to the application and the radiation-induced curing of the primer layer, for example, by means of a digital printing technique.
- the primer layer provides for a good adhesion of the applied decor onto the carrier surface coated with the primer.
- urethane acrylates offer the advantage of a good adhesion to both the carrier material and the decorative layer, i.e. the decor paint or ink. This inter alia resides in the polymerization reactions occurring in this type of polymers, in which on the one hand a radiation-induced radical polymerization of the OH groups occurs and on the other hand post-curing of the polymer via the NCO groups occurs.
- the method according to the invention enables in particular also pre-textured carriers, i.e. carriers whose surface already have a three-dimensional structure, to be provided with a primer layer, thereby ensuring that the subsequently applied decor firmly adheres to the carrier.
- the primer can be preferably applied onto the carrier plate by means of rubber rollers, a pouring device, or by spraying.
- the primer is applied in an amount between ⁇ 1 g/m 2 and ⁇ 100 g/m 2 , more preferably between ⁇ 10 g/m 2 and ⁇ 50 g/m 2 , in particular between ⁇ 20 g/m 2 and ⁇ 40 g/m 2 .
- an irradiation process by means of a radiation source of an appropriate wavelength is carried out.
- a primer it is possible to apply the decor onto a decorative paper printable with the corresponding decor, which may be provided by means of a resin layer as a bonding agent previously applied onto the carrier.
- a resin layer is suitable for flexographic printing, offset printing or screen printing as well as in particular for digital printing techniques such as inkjet processes or laser printing.
- a resin composition is applied, which as a resin component at least comprises one compound selected from the group consisting of melamine resin, formaldehyde resin, urea resin, phenol resin, epoxy resin, unsaturated polyester resin, diallyl phthalate or mixtures thereof.
- the resin composition can, for example, be applied in an area density between ⁇ 5 g/m 2 and ⁇ 40 g/m 2 , preferably ⁇ 10 g/m 2 and ⁇ 30 g/m 2 .
- a paper or a non-woven fabric with a grammage between ⁇ 30 g/m 2 and ⁇ 80 g/m 2 , preferably between ⁇ 40 g/m 2 and ⁇ 70 g/m 2 can be applied onto the plate-shaped carrier.
- a protective layer can be applied on at least a portion of the decor.
- a layer for protecting the applied decor can in particular be applied in a subsequent process step as a wearing or top layer on top of the decorative layer, and in particular protects the decorative layer against wear or damage caused by dirt, moisture or mechanical impacts, such as abrasion.
- the wearing and/or top layer is laid onto the printed carrier as a prefabricated overlay layer, such as based on melamine, and is bonded thereto by means of pressure and/or heat.
- a radiation curable composition for example a radiation curable varnish such as an acrylic varnish, is applied.
- the wearing layer includes hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, alumina (corundum), zirconia or mixtures thereof, in order to increase the wear resistance of the layer.
- the coating can be applied, for example, by means of rollers such as rubber rollers or by means of pouring devices.
- the top layer can initially be partially cured and subsequently a final coating with an urethane acrylate and a final curing step e.g. by use of a gallium emitter can be conducted.
- the top and/or wearing layer can comprise means for reducing the static (electrostatic) charging of the finished laminate.
- the top and/or wearing layer to this end comprises compounds such as choline chloride.
- the antistatic agent may, for example, be included in the composition for forming the top and/or wearing layer at a concentration between ⁇ 0,1 wt. % and ⁇ 40,0 wt. %, preferably between ⁇ 1,0 wt. % and ⁇ 30,0 wt. %.
- a texture in particular a surface texture matching with the decor is produced by introducing pores.
- the carrier plate already has a texture and an alignment of a printing tool for applying the decor with respect to the carrier plate is implemented depending on the texture of the carrier plate which is detected by means of optical methods.
- a relative movement between the printing tool and the carrier plate necessary for the alignment is implemented by shifting the carrier plate or by shifting the printing tool.
- a texturing of the decorative panel is implemented subsequently to the application of the top and/or wearing layer.
- a settable composition as the top and/or wearing layer and a curing process is done solely to the extent that only a partial curing of the top and/or wearing layer is achieved.
- a desired surface texture is embossed.
- the embossing process is implemented in correspondence with the applied decor.
- the carrier plate and the embossing tool are aligned relative to each other by corresponding relative movements.
- a further curing step is implemented with respect to the now textured top and/or wearing layer.
- a surface texture matching with the decor means that the surface of the decorative panel has a haptically perceptual structure, which according to its shape and pattern corresponds to the applied decor in order to achieve a reproduction of a natural material as close to the original as possible even with respect to the haptic.
- a counteracting means may be applied on the side opposite to the decor side.
- the counteracting means is applied in a common calendering step with the paper or non-woven fabric on the decor side.
- the decorative panel By partially profiling the decorative panel not all profiles to be provided in the finished panel are produced, but only a part of the profiles, while other profiles are produced in a subsequent step.
- the decorative profile to be provided in a panel such as a chamfer, is produced in one step, while the functional profile, e.g. groove/tongue, is produced in a subsequent step.
- the decor By means of the application of the decor subsequently to the at least partially profiling of the carrier, for example, by means of the above-described methods, such as direct printing, abrasion or damage of the decor in the course of the profiling process is avoided in an advantageous way.
- the decor also in the regions of the profile corresponds in detail the desired imitation, for example, of a natural material.
- the master used for the printing process can be distortion corrected in the region of the profile of the panel.
- Distortion correction in the sense of the invention means, for example, with respect to the exemplary case of application by means of a printing process, that the distortion of the printed image caused by the deviation of the profiling out of the surface plane of the carrier, for example, at a chamfer edge, is corrected by matching the master with the deviation.
- the correction of the distortion is implemented by matching the pixel spacing, the pixel size and/or the ink application depending on the intended edge profile of the finished decorative panel.
- the print head can be driven depending on the distortion to be corrected, such that the print head, for example, is deflected beyond the profiled region and the ink discharge is adapted to the profile.
- the joints (such as V-joints) to be provided in the final panel laminate, are milled into the carrier, on the thus profiled carrier at least the decorative layer is applied and subsequently the carrier is cut and separated at least in the profiled areas.
- the cutting method such as sawing, laser or water jet cutting, it may be preferred that the required bleed allowance is taken into account in the produced profile.
- the plate-shaped carrier can comprise a material which is based on a WPC material or a PVC material.
- a material which is based on a WPC material or a PVC material can be based on a WPC material or a PVC material.
- the decorative panel is profiled at least in an edge region of the carrier plate.
- the decor is applied also in the region of the profiling, such that the profiling can be implemented prior to the application of the decorative layer onto the plate-shaped carrier.
- a profiling can be implemented subsequently to the application of the decorative layer.
- a functional profile for example, means the introduction of a groove and/or tongue profile in an edge in order to make decorative panels connectable to each other by means of the introduced profiles.
- a decorative profile in the sense of the invention for example, is a chamfer formed at the edge region of the decorative panel, for example, in order to simulate a joint between two interconnected panels, such as for example in so-called wide planks.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/807,986 US10189300B2 (en) | 2014-04-09 | 2017-11-09 | Decorative WPC panel comprising a low-porous profiled edge and method for producing the same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP14164042.5A EP2930031B9 (de) | 2014-04-09 | 2014-04-09 | WPC-Dekorpaneel mit porenarmer Profilkante und Verfahren zur Herstellung |
EP14164042.5 | 2014-04-09 |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/807,986 Continuation US10189300B2 (en) | 2014-04-09 | 2017-11-09 | Decorative WPC panel comprising a low-porous profiled edge and method for producing the same |
Publications (1)
Publication Number | Publication Date |
---|---|
US20150290968A1 true US20150290968A1 (en) | 2015-10-15 |
Family
ID=50440589
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/669,357 Abandoned US20150290968A1 (en) | 2014-04-09 | 2015-03-26 | Decorative wpc panel comprising a low-porous profiled edge and method for producing the same |
US15/807,986 Active US10189300B2 (en) | 2014-04-09 | 2017-11-09 | Decorative WPC panel comprising a low-porous profiled edge and method for producing the same |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/807,986 Active US10189300B2 (en) | 2014-04-09 | 2017-11-09 | Decorative WPC panel comprising a low-porous profiled edge and method for producing the same |
Country Status (4)
Country | Link |
---|---|
US (2) | US20150290968A1 (pl) |
EP (1) | EP2930031B9 (pl) |
CN (1) | CN104975695B (pl) |
PL (1) | PL2930031T3 (pl) |
Cited By (4)
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US20170217133A1 (en) * | 2016-01-28 | 2017-08-03 | American Aquawood, Inc. | Floor and Wall Covering Assembly |
US20180186957A1 (en) * | 2017-01-05 | 2018-07-05 | City University Of Hong Kong | Composite material composition and a method of forming a composite material composition |
US20180216353A1 (en) * | 2015-07-22 | 2018-08-02 | Akzenta Paneele + Profile Gmbh | Panel |
US11518147B2 (en) * | 2017-06-08 | 2022-12-06 | Kuraray Europe Gmbh | Method for recycling intermediate film for laminated glass |
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DE102017125744A1 (de) * | 2017-11-03 | 2019-05-09 | Falquon Gmbh | Verfahren zur Herstellung einer dekorierten Oberfläche eines Gegenstandes |
CN115989131A (zh) * | 2020-09-02 | 2023-04-18 | 塞拉洛克创新股份有限公司 | 用于在板块元件中形成沟槽的方法和设施 |
WO2024054150A1 (en) * | 2022-09-07 | 2024-03-14 | Välinge Innovation AB | Method to manufacture a bevel on a building panel and such building panel |
NL2033198B1 (en) * | 2022-09-30 | 2024-04-08 | Champion Link Int Corp | Panel, composition for impregnating or coating a panel, and a method for producing a panel |
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180216353A1 (en) * | 2015-07-22 | 2018-08-02 | Akzenta Paneele + Profile Gmbh | Panel |
US10612248B2 (en) * | 2015-07-22 | 2020-04-07 | Akzenta Paneele + Profile Gmbh | Panel |
US20170217133A1 (en) * | 2016-01-28 | 2017-08-03 | American Aquawood, Inc. | Floor and Wall Covering Assembly |
US20180186957A1 (en) * | 2017-01-05 | 2018-07-05 | City University Of Hong Kong | Composite material composition and a method of forming a composite material composition |
US10737458B2 (en) * | 2017-01-05 | 2020-08-11 | City University Of Hong Kong | Composite material composition and a method of forming a composite material composition |
US11518147B2 (en) * | 2017-06-08 | 2022-12-06 | Kuraray Europe Gmbh | Method for recycling intermediate film for laminated glass |
Also Published As
Publication number | Publication date |
---|---|
CN104975695B (zh) | 2018-11-02 |
EP2930031B9 (de) | 2018-04-25 |
EP2930031B1 (de) | 2018-01-17 |
US10189300B2 (en) | 2019-01-29 |
CN104975695A (zh) | 2015-10-14 |
PL2930031T3 (pl) | 2018-07-31 |
US20180065405A1 (en) | 2018-03-08 |
EP2930031A1 (de) | 2015-10-14 |
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Legal Events
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AS | Assignment |
Owner name: AKZENTA PANEELE + PROFILE GMBH, GERMANY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HANNIG, HANS-JURGEN;REEL/FRAME:035262/0951 Effective date: 20150310 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |