WO2010084386A2 - Procédés de fabrication de panneaux et panneau ainsi obtenu - Google Patents

Procédés de fabrication de panneaux et panneau ainsi obtenu Download PDF

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Publication number
WO2010084386A2
WO2010084386A2 PCT/IB2009/055706 IB2009055706W WO2010084386A2 WO 2010084386 A2 WO2010084386 A2 WO 2010084386A2 IB 2009055706 W IB2009055706 W IB 2009055706W WO 2010084386 A2 WO2010084386 A2 WO 2010084386A2
Authority
WO
WIPO (PCT)
Prior art keywords
print
printing units
print portion
pass
digital printing
Prior art date
Application number
PCT/IB2009/055706
Other languages
English (en)
Other versions
WO2010084386A3 (fr
Inventor
Laurent Meersseman
Original Assignee
Flooring Industries Limited, Sarl
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Flooring Industries Limited, Sarl filed Critical Flooring Industries Limited, Sarl
Publication of WO2010084386A2 publication Critical patent/WO2010084386A2/fr
Publication of WO2010084386A3 publication Critical patent/WO2010084386A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/0015—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form for treating before, during or after printing or for uniform coating or laminating the copy material before or after printing
    • B41J11/002—Curing or drying the ink on the copy materials, e.g. by heating or irradiating
    • B41J11/0021—Curing or drying the ink on the copy materials, e.g. by heating or irradiating using irradiation
    • B41J11/00214—Curing or drying the ink on the copy materials, e.g. by heating or irradiating using irradiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/0015—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form for treating before, during or after printing or for uniform coating or laminating the copy material before or after printing
    • B41J11/002—Curing or drying the ink on the copy materials, e.g. by heating or irradiating
    • B41J11/0021—Curing or drying the ink on the copy materials, e.g. by heating or irradiating using irradiation
    • B41J11/00216—Curing or drying the ink on the copy materials, e.g. by heating or irradiating using irradiation using infrared [IR] radiation or microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/0015—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form for treating before, during or after printing or for uniform coating or laminating the copy material before or after printing
    • B41J11/002—Curing or drying the ink on the copy materials, e.g. by heating or irradiating
    • B41J11/0022—Curing or drying the ink on the copy materials, e.g. by heating or irradiating using convection means, e.g. by using a fan for blowing or sucking air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/54—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed with two or more sets of type or printing elements
    • B41J3/543—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed with two or more sets of type or printing elements with multiple inkjet print heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/008—Sequential or multiple printing, e.g. on previously printed background; Mirror printing; Recto-verso printing; using a combination of different printing techniques; Printing of patterns visible in reflection and by transparency; by superposing printed artifacts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0041—Digital printing on surfaces other than ordinary paper
    • B41M5/0047—Digital printing on surfaces other than ordinary paper by ink-jet printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/009—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using thermal means, e.g. infrared radiation, heat

Definitions

  • This invention relates to methods for manufacturing panels, as well as to panels which can be obtained by such methods.
  • the invention relates to methods for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on this substrate, said top layer comprising a printed decor.
  • this may relate, for example, to furniture panels, ceiling panels, floor panels or the like, which substantially consist of a MDF or HDF (Medium or High Density Fiberboard) basic panel or substrate and a top layer provided thereon.
  • this relates to a method in which one or more material layers are provided on the substrate, wherein at least one of these material layers is provided by means of a print performed directly on the panel or the substrate, wherein this print then forms at least a portion of said printed decor.
  • Such panels are known as such, for example, from US 1 ,971 ,067 or DE 195 32 819 A1.
  • the invention relates to a method which comprises at least a step in which said decor is formed directly on the panel by a print by means of two or more digital printing units.
  • the use of digital printing techniques for forming such decor is known as such, for example, of WO 01/48333 or EP 1 872 959.
  • said material layers may comprise one or more basic layers, wherein these basic layers substantially extend underneath said print, and/or may comprise one or more finishing layers which substantially extend above said print.
  • finishing layers may comprise, for example, transparent or translucent synthetic material layers, which form a protective layer above the printed decor and may comprise, for example, wear- resistant particles, such as aluminum oxide.
  • this protective layer comprises a material sheet, such as a paper sheet.
  • a suitable basic layer is important in particular for digital printing techniques, as such basic layer, on the one hand, must have sufficient affinity for the adherence of the applied colorants or inks, however, on the other hand, may not be too porous in order to avoid that the applied colorants or inks might be absorbed in an excessive manner by this underlying layer or the substrate.
  • These difficulties may lead to a sub-optimal printing quality.
  • these difficulties are still more prominently present when water-based inks are used.
  • working with water- based inks is more advantageous than working with solvent-based inks.
  • porous substrates such as MDF or HDF (Medium or High Density Fiberboard)
  • porous basic layers such as basic layers comprising one or more paper sheets.
  • point-wise applied ink droplets may have the tendency of flowing into each other, such that in such case, too, a reduced printing quality will be noticed.
  • the print heads may be adjusted, with the intention of limiting the total amount of ink, for depositing only a limited amount of basic color.
  • the print heads may be adjusted, with the intention of limiting the total amount of ink, for depositing only a limited amount of basic color.
  • the print heads may be adjusted, with the intention of limiting the total amount of ink, for depositing only a limited amount of basic color.
  • this compared to the other colors, may lead to an irregular deficit of basic color with red pigment.
  • cyan, magenta, yellow and black (CMYK) such adjustment thus may lead to an irregular deficit of magenta.
  • wood patterns comprise many red and/or brown tints, and the required amount of magenta ink may reach the maximum adjusted amount earlier than the required amount of ink of the other colors, which results in an unjust color rendition.
  • the present invention in first instance relates to an alternative method for manufacturing panels, which method, according to various preferred embodiments thereof, allows obtaining a better printing quality without necessitating a modification of the basic layer which possibly has to be applied.
  • the invention relates to a method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on this substrate, said top layer comprising a printed decor, wherein the method comprises at least a step in which said decor is formed directly on the panel by a print by means of two or more digital printing units, with the characteristic that the method also comprises a drying treatment, in which the print or the obtained print portion is at least partially dried in a forced manner, wherein the print portion provided by a first of said two digital printing units is exposed to the drying operation and herein is at least partially dried before a second of said two digital printing units is active at the location of this print portion concerned.
  • the drying may lead, for example, to a fixation of the applied print portion.
  • said digital printing techniques are of the type which can deposit ink droplets in a point- wise manner, such as this is the case, for example, with Drop-on-Demand (DOD) inkjet systems.
  • a forced manner it is meant that the respective drying operation is not performed by a mere exposition to the surrounding air, but is performed, for example, by means of heated air, forced air flow, radiation heat and/or heat supplied to the panel in another manner and/or created in the panel.
  • the respective print portions are provided on identically the same place, however, it is meant that the surface covered by said second digital printing unit is at least partially overlapping the surface covered by said first digital printing unit.
  • the individual ink droplets of the respective print portions may be completely separated from each other. It is also possible that the ink droplets of the respective print portions overlap each other.
  • so-called single-pass inkjet systems as well as so- called multi-pass inkjet systems may be applied.
  • a print is realized by a single movement or pass of one or more print heads relative to the surface to be printed.
  • the print heads are stationary during printing, whereas the surface to be printed will pass underneath the print heads, and such preferably in a continuous manner.
  • a print is realized in multiple movements or passes of one or more print heads relative to the surface to be printed.
  • the print portions realized in each of these passes may be performed with a shifting in mutual respect.
  • the panel to be printed will be stationary during such pass while the print head or print heads move thereover. Between two passes, said shifting may be performed, for example, in that the print head or print heads are adjusted transversely to the printing direction.
  • the two or more printing units ⁇ of the invention in the case of a multi- pass inkjet system may relate to one and the same print head forming said decor in at least two passes directly on the panel, as well as to two separate print heads printing the panel one after the other.
  • at least a partial drying is performed, in the first case preferably before the same print head is a second time active at the location of an earlier provided print portion, and in the second case preferably before the second print head is active at the location of an earlier provided print portion.
  • a drying unit may be positioned between said two printing units, and/or both printing units may be positioned in a common drying unit.
  • at least the first of said two print units can be provided with a drying unit and/or said forced drying can be performed with a separate drying unit.
  • the board can be provided in such drying unit or can be transported there through, or such drying unit can be moved relative to the board.
  • drying unit for example, one or more hot-air ovens, UV radiators or IR radiators can be applied.
  • drying operation is performed by heat or energy which has been supplied to the panel prior to realizing the respective print portion.
  • printing may be performed on heated substrates or panels.
  • realizing a print or a print portion on heated substrates or panels as such forms an independent inventive aspect of the invention, irrespective of the fact whether a digital or an analogous printing technique is applied.
  • the temperature of the panels may be, for example, between 20 0 C and 55°C or may even rise to 80 0 C or more.
  • particle board, MDF or HDF boards use can be made of boards which are still warm from a press treatment having taken place during their manufacture.
  • the respective substrates, panels or boards, prior to being printed are fed into an oven or are heated in another manner.
  • they may be supplied by means of a heated transport device and/or they may be provided on a heated table during printing.
  • drying may be caused by a chemical reaction, whether or not taking place as a consequence of applying the respective print portion.
  • inks may be used which are modified with an agent which can react with the respective basic layer and/or the substrate, which as such also forms an independent aspect of the invention, irrespective of the fact whether a digital or analogous printing technique is applied.
  • drying by means of a chemical reaction may take place, for example, when the chemical reaction as such is exothermic, or when the chemical reaction results in reaction products which are less moist than the reagents, or even are solid.
  • the inventive idea of the method of the first aspect also can be formulated in another manner and that the invention thus in fact relates to a method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on this substrate, said top layer comprising a printed decor, wherein the method comprises at least a step wherein said decor is formed directly on the panel by means of a print performed with a digital printing device, with the characteristic that the method also comprises a drying treatment, in which the print is at least partially dried in a forced manner, wherein the step of forming the decor comprises at least applying a first print portion and applying a second print portion at the location of the first print portion, wherein the first print portion is exposed to said drying operation before the second print portion is applied.
  • the print portion can cover any surface. This may relate, for example, to one or more printed points, or, for example, to a monochromatic print portion covering approximately the entire panel.
  • each digital printing unit is subjected to such forced drying operation preferably immediately after the application thereof. It is clear that such embodiment of the present method can be obtained by providing a drying unit after each printing unit and/or by performing the printing respectively on heated panels and/or by working with heated inks. In the case of a multi-pass inkjet system, this can be performed by providing one or more or all print heads with a drying device or by interposing a drying treatment after each printing pass, for example, by means of a drying unit which moves over the panel.
  • inkjet printing units are applied as digital printing units, which preferably as such respectively form a monochromatic print portion.
  • each printing unit or print head solely works with ink of one color.
  • at least use can be made of standard colors which, by means of the principle of color addition or color subtraction, allow forming a large variety of different colors, and still better allow forming substantially all colors, such as it may be the case with printing units respectively forming cyan, magenta, yellow and possibly black monochromatic print portions.
  • the combination of at least red, green, blue and possibly black may be chosen.
  • said digital printing units are of the type which is stationary, wherein said printing then is performed as the panel moves along the printing units.
  • one or more printing units cover the entire surface to be printed of the respective panel, such that this surface can be provided with the printed decor concerned in a single movement along the printing units.
  • Such "single-pass" arrangement of printing units is known as such, for example, from the aforementioned document EP 1 872 959.
  • said printing is performed in a single movement along the respective digital printing units.
  • printing units which each apply a monochromatic print portion, to this aim preferably per color a number of print heads, possibly only one, are arranged, which allow covering the entire surface to be printed.
  • the panel during printing, preferably has a speed of more than 30 m/min and still better of more than 80 m/min. Speeds up to 150 m/min are not excluded.
  • solvents may be chosen having a relatively low evaporation temperature.
  • the inks may be heated beforehand, such that less energy has to be added for obtaining the evaporation temperature.
  • inks having a temperature of more than 20 0 C, and still better of more than 25°C or even more than 40 0 C as such relates to an inventive aspect of the present invention, irrespective of the fact whether a digital printing technique or an analogous printing technique is applied for forming a printed decor on a panel.
  • higher temperatures are not excluded.
  • a higher application temperature may have advantages.
  • the temperature of the inks is high enough, the printing line possibly may be run without drying units. Such arrangement is advantageous in respect to energy consumption.
  • the heating of inks may be performed such that it always consumes less energy than keeping a hot-air oven or the like on its operating temperature.
  • said digital printing units form part of a multipass printing device.
  • each of said printing units performs a print consisting of 6 to 32 print portions performed in respective passes, or still better between 8 and 24 print portions in respective passes.
  • At least four digital printing units or print heads are applied, wherein these printing units as such each form a monochromatic print portion.
  • said digital printing units preferably form a multi-colored print, for example, at least on the basis of the colors cyan, magenta, yellow and black.
  • at least a fifth color is used in addition to the colors cyanrmagenta, yellow and black.
  • this fifth color is adapted to the tint of the print to be formed.
  • these five colors, as aforementioned, respectively are provided by at least one printing unit, which, by means of the respective color, as such forms a monochromatic print portion.
  • the substrate is provided with one or more material layers, which form a basic layer for the print.
  • the material layers known as such may be used.
  • Such basic layer may be of uniform or at least quasi-uniform color.
  • a basic layer may be formed having the basic color of the printed decor to be formed thereon.
  • unevennesses at the surface of the substrate possibly may be filled with a material layer comprising a filler.
  • a sealing material layer can be used, and/or a material layer serving as a primer for retaining the colorants, such as inks and paints, which are to be applied at a later moment. So, for example, one or more ink-receptive layers can be applied.
  • said material layers can be applied simpler, more precisely and/or smoothly on larger surfaces than on the surfaces of smaller panels.
  • the method of the invention is applied for manufacturing floor, wall or ceiling panels of restricted surface, it is started from larger boards of substrate material, wherein one or more of said material layers are provided on the surface of these larger boards, these larger boards are subdivided into smaller panels and said print is performed at least partially on those smaller panels.
  • said larger board, during said subdividing is divided into panels having a size which corresponds, or at. least approximately corresponds, to the final panels. It is also possible that subdividing is performed only after completing the printing.
  • such basic layers or other material layers are applied in liquid form.
  • said first material layer preferably relates to a basic layer or primer layer.
  • one or more rollers can be applied, and/or jetting or spraying devices can be used.
  • said material layers comprise a material sheet, such as a paper layer or a foil. In this case, this can be provided by means of a press treatment.
  • Such material sheet can be provided with synthetic material, for example, with a synthetic material which can realize the bonding with the-board surface: For example, use can be made of an amino resin, such as melamine formaldehyde resin. However, also a glue may be used, such as phenol glue.
  • an amino resin such as melamine formaldehyde resin
  • an amino resin such as melamine formaldehyde resin
  • melamine formaldehyde resin also can be provided in liquid form on the board surface without using such material sheets.
  • one or more material layers comprising material sheets best one or more or still better all such material sheets are provided on the surface of a larger board.
  • Application techniques which are suitable for applying material layers, are more advantageous when being utilized on larger surfaces.
  • water-based inks are applied in said digital printing units.
  • these inks are less expensive than solvent-based inks.
  • solvent-based inks would be applied in said digital printing units.
  • At least an infrared or an UV radiator are used, for example, in the form of one or more lamps.
  • the present invention also relates to a method for manufacturing panels, wherein more lively decors can be obtained.
  • the invention relates to a method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on this substrate, said top layer comprising a printed decor, wherein the method comprises at least a step in which said decor is formed directly on the panel by a print by means of digital printing units, with the characteristic that at least five digital printing units are used, wherein each of these five digital printing units respectively forms a monochromatic print portion of different color.
  • said five different colors comprise at least cyan, magenta, yellow and black. These colors as such already allow forming a large variety of different colors.
  • said five colors comprise at least two different colors which are obtained on the basis of an ink comprising red pigment.
  • an ink comprising red pigment may work, for example, with at least one other color, which is obtained on the basis of an ink comprising red pigment.
  • the color concerned may relate to a red or brown tint. Red pigment is of particular importance when forming printed decors with a wood pattern. It is clear that according to the invention, it is not required that said two colors, which comprise red pigment, should at least comprise magenta.
  • the method preferably further also comprises the step of forming profiled edge regions at the panels, wherein this step preferably is performed prior to applying a possible finishing layer.
  • profiled edge regions preferably comprise coupling means allowing to interconnect two or more of such floor panels at their edges.
  • this relates to coupling means allowing for a glue-free connection, such as known as such, for example, from the document WO 97/47834.
  • these preferably have a surface of less than 0.5 m 2 , or of even less than 0.3 m 2 .
  • the thickness of such floor panels may vary between 5 and 25 mm, or still better is situated between 6 and 15 millimeters.
  • a transparent finishing layer is provided above the print.
  • Such material layer possibly may comprise a material sheet, such as a paper sheet, however, may also substantially consist of synthetic material.
  • a lacquer such as a UV-hardening or electron beam-hardening lacquer
  • a thermically hardening layer such as a melamine-containing thermically hardening layer.
  • Such transparent material layer preferably also comprises hard particles, for example, aluminum oxide particles.
  • the invention according to all of its aspects is applied for obtaining a printed decor representing a wood pattern. Other motifs, such as stone patterns or fantasy motifs, are not excluded. In the case of floor panels, preferably one plank is represented per panel.
  • the invention preferably is applied for manufacturing floor panels and/or panels of which said substrate material substantially consists of MDF or HDF or another wood-based material.
  • inkjet printing is well suited for performing prints on the surface of smaller panels, which already approximately show the dimensions of the final panels. However, it is not excluded that the print is performed on larger panels, which still have to be subdivided in order to arrive at the final panels. The inventor has found that it is particularly advantageous to apply multi-pass inkjet systems for printing such larger boards.
  • the invention in an independent manner relates to a method for manufacturing panels, wherein it is started from larger boards, with the characteristic that the method comprises at least a step in which a print is formed directly on the larger board, by means of a multi-pass inkjet system, and wherein the method also comprises a step in which the larger board provided with the print is subdivided into two or more smaller panels.
  • the invention of this independent aspect further also shows the characteristics of one or more of the above-mentioned aspects and/or the preferred embodiments thereof.
  • said print is performed after said boards are provided with one or more basic layers.
  • at least 2 basic layers are applied.
  • Such basic layers preferably are white or beige.
  • said print is performed after the substrate and/or said basic layers are subjected to at least one grinding treatment.
  • grinding is performed at least once in longitudinal direction and at least once in transverse direction. In this manner, a very good basis for printing can be realized.
  • such board after printing has been accomplished, also is provided with one or more finishing layers, and preferably prior to said subdividing.
  • this relates to finishing layers on the basis of an amino resin, such as on the basis of melamine resin.
  • an amino resin such as on the basis of melamine resin.
  • also translucent or transparent lacquers may be used.
  • the material of the finishing layers is brought onto the board without applying material sheets as carriers.
  • such material can be deposited in liquid form, for example, by means of one or more rollers. After this material possibly has dried, then, for example, in the case of an amino resin, also a press operation may be applied. By means of such press operation, a structure can be obtained at the surface of the respective board.
  • finishing layers further may also comprise hard particles, such as aluminum oxide, by which an improved wear resistance is obtained at the surface of the final panels.
  • such particles are provided on the still wet finishing layer or finishing layers by means of a strewing device.
  • the invention in an independent manner further also relates to a method for manufacturing panels, wherein the method comprises at least a step in which, by means of a multi-pass inkjet system, a print is formed directly on the panel or on a larger board, from which panels are obtained by subdividing, wherein said step of forming the print comprises at least applying a first print portion in a first pass and applying a second print portion in a second pass, with the characteristic that one or more ink droplets of the print portion provided in the second pass overlap with one or more ink droplets of the print portion provided in the first pass.
  • the majority of the ink droplets of the print portion provided in the second pass show an overlapping with one or more ink droplets of the print portion provided in the first pass.
  • at least 5 percent and still better at least 10 percent or at least 20 percent of the surface of an ink droplet of a print portion is made overlapping with ink droplets of print portions of preceding passes or subsequent passes.
  • the invention also relates to panels having a printed decor, wherein at least a part of the ink droplets forming said printed decor, and preferably at least 20% or 30% thereof, are made overlapping. Said overlaps may be present in printing direction and/or transverse to this printing direction.
  • the overlap realized according to the above fourth aspect of the invention preferably can be applied for realizing relatively dark printed decors, such as, for example, when imitating a tropical wood species, such as wenge, jatoba, merbau and the like.
  • Such overlap namely has the advantage that a better covering degree of the print on the underlying layers and/or the substrate may be achieved, as a consequence of which more intense colors may be achieved.
  • the overlap of the fourth aspect also leads to minimizing the also above- mentioned risk of defects in the print. Namely, the absence of ink droplets during one or more of the passes is less visible.
  • the print portions realized in each of the passes can be realized with a shifting in mutual respect.
  • said shifting preferably is smaller than the average diameter of the ink droplets which are provided in the subsequent step.
  • said shifting is minimum 60% or still better at least 75% of said average diameter of the ink droplets.
  • the invention according to a fifth aspect in an independent manner relates to a method for manufacturing panels, wherein the method comprises at least a step in which, by means of a multi-pass inkjet system, a print is formed directly on the panel or on a larger board, from which panels are obtained by subdividing, wherein said step of forming the print comprises at least applying a first print portion in a first pass and applying a second print portion in a second pass, with the characteristic that the print portions in the second pass are performed with a shifting in respect to said first pass, wherein said shifting is smaller than the average diameter of the ink droplets which are provided in said second pass.
  • said first pass and second pass preferably follow each other. This means that they preferably are performed without performing other print portions in between. However, this is not necessarily the case.
  • the shifting which is applied according to the above-mentioned fifth aspect of the invention preferably can be applied for realizing relatively dark printed decors, such as, for example, when imitating a tropical wood species, such as wenge, jatoba, merbau and the like.
  • Such shifting namely has the advantage that a better covering degree of the print on the underlying layers and/or the substrate can be achieved, by which more intense colors can be achieved.
  • the shifting of the fifth aspect also leads to minimizing the also above-mentioned risk of defects in the print. Namely, the absence of ink droplets during one or more of the passes will be less visible.
  • a drying treatment is performed at least on a portion of the print.
  • at least a partial fixation of the ink droplets applied in the respective pass can be obtained. It is clear that in this case an embodiment of the first aspect of the invention is obtained.
  • the invention also relates to a panel which is obtained by means of a method with the characteristics of any aspect of the invention, or combinations thereof. Preferably, this relates to a floor panel.
  • Figure 1 schematically represents some steps in a method with the characteristics of the invention
  • Figure 2 represents a view according to the direction F2 represented in
  • Figure 3 in perspective and schematically represents a step in a method with the characteristics of, amongst others, the third aspect of the invention
  • Figure 4 at a larger scale, represents a view on the area F4 indicated in figure 3;
  • Figure 5 in a similar view represents a variant.
  • Figure 1 schematically represents some steps S0-S1-S2 in a method for manufacturing panels, in this case, floor panels 1.
  • the floor panel is of the type which is at least composed of a substrate 2, in this case a wood-based substrate 2, such as MDF or HDF, and a top layer 3 provided on this substrate 2.
  • Figure 2 represents that the top layer 3 of the manufactured floor panel 1 shows a decor 4, in this case a printed decor 4 with a wood pattern, more particularly a wood pattern representing only one wood part.
  • this relates to oblong floor panels 1.
  • such panels 1 also may be provided with coupling means at least at two opposite edges 5-6 and/or 7-8, said coupling means allowing to interconnect two or more of such floor panels.
  • this may relate to a tongue and groove connection for gluing together, or to gluelessly connectable coupling profiles.
  • Such coupling means are not represented here, however, they are known, for example, from the document WO 97/47834.
  • Figure 1 clearly shows that the method comprises at least a step S1 , wherein said decor 4 is formed directly on the panel 1 by a print by means of two or more digital printing units 9A-9B-9C-9D-9E.
  • the substrate 2 of the panel 1 can be provided with one or more material layers in a preceding step SO, wherein these material layers form a basic layer 10 for the print to be performed thereon.
  • these material layers may be applied in liquid form, for example, such as here by means of a roller 11.
  • the underside 12 of the substrate 2 can be provided with a material layer, whether or not being applied in liquid form.
  • it is possible to provide these material layers 10 on a larger board, which subsequently is subdivided into panels 1 for example, by means of a sawing treatment.
  • the printing device 13 represented here makes use of at least four digital printing units 9A-9B-9C-9D, in this case, stationary inkjet print heads, which extend over the entire width B1 to be printed of the panel 1 concerned.
  • each printing unit 9A-9B-9C-9D is intended for realizing a monochromatic print portion while the respective panel 1 moves along the printing units 9A-9B-9C-9D.
  • the totality of the printed decor 4 is formed substantially or entirely during a single movement T along the inkjet print heads or printing units 9A-9B-9C-9D.
  • the higher speeds are of particular interest when the printed panels 1 in the same production line still have to be provided with profiled edge regions by means of, for example, a milling operation. These milling operations usually are performed at speeds higher than 100 m/min.
  • a plurality of stationary printing units 9A can be applied for providing the entire width B1 of the surface to be printed with a monochromatic print portion of the same color.
  • the width B1 of the surface to be printed does not necessarily correspond to the width B2 of the panel 1 to be printed.
  • unprinted edges 5A-6A may be present at one or more sides 5-6 of this panel, said edges, for example, corresponding or approximately corresponding to material zones to be removed. In these material zones, for example, the also above-mentioned coupling means or other profiled edges regions may be formed.
  • the inkjet print heads or printing units 9A-9B-9C-9D respectively apply a monochromatic print portion on the basis of cyan, magenta, yellow and black ink.
  • this thus relates to a so-called printing with CMYK colors.
  • dashed line 14 it is represented that except printing units 9A-9B-9C-9D for the colors cyan, magenta, yellow and black, respectively, also at least a fifth printing unit 9E can be applied for forming a monochromatic print portion in a fifth color.
  • a fifth or further color then specifically is adapted to the decor 4 to be formed.
  • a red tint or a brown tint is applied as the fifth color, or, in other words, in the extra printing unit 9E preferably an ink is applied which comprises red pigment, however, which differs from the ink forming said magenta.
  • the particularity of the invention according to its first aspect consists in that the method also comprises a drying treatment 15A, in which the print or the obtained print portion is at least partially dried in a forced manner.
  • a drying treatment 15A in which the print or the obtained print portion is at least partially dried in a forced manner.
  • the print portion applied by a digital printing unit 9A-9B-9C-9D-9E respectively is exposed to a subsequent drying operation 15A-15B-15C-15D-15E, before a following digital printing unit is active at the location of this respective print portion.
  • a drying unit 16 is arranged after each printing unit 9A-9B-9C- 9D-9E.
  • this may relate, for example, to hot-air ovens or UV lamps, depending on the applied inks.
  • one or more print portions are not forcedly dried before a following digital printing unit 9B is active at the location of the respective print portion.
  • a drying treatment 15A is provided at least on one location between the printing units 9A-9B, an improved printing quality can be obtained in comparison with the techniques of the state of the art.
  • a drying treatment 15E is applied until, for example, a complete drying of the inks is achieved, or at least an acceptable drying, which allows that further treatments of the panel 1 and/or stacking the printed panels 1 is possible.
  • the printed panel 1 can be provided with one or more material layers, which form a transparent or translucent finishing layer 17 above the printed decor 4.
  • finishing layer may be realized by means of a lacquer layer and/or melting glue (hot melt).
  • lacquer may relate, for example, to an UV-hardening or electron beam-hardening lacquer, which, for example, comprises wear-protective particles, such as aluminum oxide.
  • Figure 1 represents that such finishing layer 17 can be applied at least partially in liquid form.
  • rollers can be used, and/or, as represented, the technique of curtain pouring and/or the technique of vacuum coating.
  • Figure 3 schematically represents a variant for the step S1 represented in the figure.
  • a multi-pass printing device 13 is applied for printing the substrate 2, which in this case comprises a larger board 18, from which, by subdividing, two or more floor panels or other panels 1 can be obtained. It is clear that such embodiment shows the characteristics of the third- aspect- of the invention mentioned in the introduction. Preferably, already one or more basic layers are situated on the substrate before printing is started.
  • Figure 3 represents that the printing device 13 comprises a plurality of printing units 9, which each in several passes perform a portion of the print.
  • the second pass is performed.
  • the arrangement 20 of printing units 9 moves over the board 18, whereas this board 19 is stationary.
  • the arrangement 20 of printing units is shifted in transverse direction over a distance D1 in comparison with its position during the first pass.
  • the first print portion 21 applied in said first pass, and the second print portion 22, applied in said second pass, are performed with a shifting over a distance D1 in mutual respect.
  • Figure 4 clearly shows that the distance D1 of the shifting is smaller than the average diameter D2 of the ink droplets 23 of the print portions 21-22 provided in said first and/or second pass.
  • the ink droplets 23 provided during the respective passes overlap each other.
  • the respective overlaps 24 are present in printing direction T as well as transverse to the printing direction T.
  • Figure 5 represents a variant in which the central points of the majority of the ink droplets 23 applied in the first and the second pass are shifted in mutual respect in the printing direction T.
  • Figure 3 also represents an example of the first aspect of the invention.
  • the arrangement 20 of printing units 9 is provided with a drying device 15, the first print portion 21 can be subjected to a drying treatment prior to performing the second print portion 22.

Landscapes

  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Ink Jet (AREA)
  • Finishing Walls (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Printing Methods (AREA)

Abstract

L'invention porte sur un procédé de fabrication de panneaux du type qui est au moins constitué d'un substrat (2) et d'une couche supérieure (3) disposée sur ce substrat (2), ladite couche supérieure comportant une décoration imprimée (4), le procédé comportant au moins une étape (S1) dans laquelle ladite décoration (4) est formée directement sur le panneau (1) au moyen d'une impression effectuée avec un dispositif d'impression numérique, étant caractérisé en ce que le procédé comporte également un traitement de séchage (15A-15B-15C-15D), dans lequel l'impression ou la partie d'impression obtenue est au moins partiellement séchée d'une façon forcée, l'étape (S1) de formation de la décoration (4) comportant au moins l'application d'une première partie d'impression et l'application d'une seconde partie d'impression à l'emplacement de la première partie d'impression, la première partie d'impression étant exposée à l'opération de séchage (15A) avant que la seconde partie d'impression ne soit appliquée.
PCT/IB2009/055706 2009-01-20 2009-12-11 Procédés de fabrication de panneaux et panneau ainsi obtenu WO2010084386A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BE2009/0035A BE1018630A5 (nl) 2009-01-20 2009-01-20 Werkwijzen voor het vervaardigen van panelen en paneel hierbij bekomen.
BEBE2009/0035 2009-01-20

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WO2010084386A2 true WO2010084386A2 (fr) 2010-07-29
WO2010084386A3 WO2010084386A3 (fr) 2010-09-30

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DE102010045266A1 (de) * 2010-09-14 2012-03-15 Guido Schulte Verfahren zur Herstellung eines Bauteils zur Verkleidung sowie Bauteil zur Verkleidung
EP2644391A1 (fr) 2012-03-30 2013-10-02 Tarkett GDL S.A. Dispositif d'impression, procédé correspondant et produit imprimé
EP2789476A1 (fr) 2013-04-09 2014-10-15 Tarkett GDL S.A. Procédé pour la fabrication de substrats imprimés numériquement
ITPN20130029A1 (it) * 2013-06-06 2014-12-07 Silvano Ros Processo per realizzazione elementi di arredo
EP2894044A1 (fr) * 2014-01-10 2015-07-15 Agfa Graphics Nv Fabrication de stratifiés décoratifs par impression à jet d'encre
EP2844495A4 (fr) * 2012-04-30 2016-01-20 Vaelinge Innovation Ab Procédé pour former un motif décoratif sur un élément d'un matériau à base de bois
US9605168B2 (en) 2014-01-31 2017-03-28 Ceraloc Innovation Ab Digital print with water-based ink
US9994010B2 (en) 2014-01-24 2018-06-12 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US10017950B2 (en) 2011-08-26 2018-07-10 Ceraloc Innovation Ab Panel coating
EP3498479A1 (fr) * 2017-12-18 2019-06-19 OCE Holding B.V. Procédé d'impression de bandes d'une image sur un substrat
US10328680B2 (en) 2013-10-23 2019-06-25 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
US10369837B2 (en) 2012-04-30 2019-08-06 Valinge Innovation Ab Method for forming a decorative design on an element of a wood-based material
WO2019170456A1 (fr) * 2018-03-09 2019-09-12 Agfa Nv Procédé de fabrication de panneaux décoratifs
US11186997B2 (en) 2016-03-24 2021-11-30 Valinge Innovation Ab Method for forming a décor on a substrate

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DE19532819A1 (de) 1995-09-06 1997-03-13 Hofa Homann Verwaltungsgesells Verfahren zur Herstellung einer Holzwerkstoffplatte
WO1997047834A1 (fr) 1996-06-11 1997-12-18 Unilin Beheer B.V. Revetement de sol compose de panneaux de plancher durs et procede de fabrication de ces panneaux de plancher
WO2001048333A1 (fr) 1999-12-23 2001-07-05 Perstorp Flooring Ab Procede de fabrication d'elements de surface
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Cited By (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010045266A1 (de) * 2010-09-14 2012-03-15 Guido Schulte Verfahren zur Herstellung eines Bauteils zur Verkleidung sowie Bauteil zur Verkleidung
DE102010045266B4 (de) 2010-09-14 2022-07-07 Guido Schulte Verfahren zur Herstellung eines Bauteils zur Verkleidung sowie Bauteil zur Verkleidung
US10017950B2 (en) 2011-08-26 2018-07-10 Ceraloc Innovation Ab Panel coating
EP2644391A1 (fr) 2012-03-30 2013-10-02 Tarkett GDL S.A. Dispositif d'impression, procédé correspondant et produit imprimé
EP2844495A4 (fr) * 2012-04-30 2016-01-20 Vaelinge Innovation Ab Procédé pour former un motif décoratif sur un élément d'un matériau à base de bois
US10369837B2 (en) 2012-04-30 2019-08-06 Valinge Innovation Ab Method for forming a decorative design on an element of a wood-based material
RU2619095C2 (ru) * 2012-04-30 2017-05-11 Велинге Инновейшн Аб Способ формирования декоративного узора на элементе из древесного материала
EP2789476A1 (fr) 2013-04-09 2014-10-15 Tarkett GDL S.A. Procédé pour la fabrication de substrats imprimés numériquement
ITPN20130029A1 (it) * 2013-06-06 2014-12-07 Silvano Ros Processo per realizzazione elementi di arredo
US11077652B2 (en) 2013-10-23 2021-08-03 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
US10328680B2 (en) 2013-10-23 2019-06-25 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
AU2015205708B2 (en) * 2014-01-10 2019-02-14 Agfa Nv Manufacturing of decorative laminates by inkjet
US9855767B2 (en) 2014-01-10 2018-01-02 Agfa Graphics Nv Manufacturing of decorative laminates by inkjet
EP2894044A1 (fr) * 2014-01-10 2015-07-15 Agfa Graphics Nv Fabrication de stratifiés décoratifs par impression à jet d'encre
CN105873771B (zh) * 2014-01-10 2018-12-25 爱克发有限公司 通过喷墨制造装饰性层压材料
WO2015104249A1 (fr) * 2014-01-10 2015-07-16 Agfa Graphics Nv Fabrication de stratifiés décoratifs par jet d'encre
CN105873771A (zh) * 2014-01-10 2016-08-17 爱克发印艺公司 通过喷墨制造装饰性层压材料
US10899121B2 (en) 2014-01-24 2021-01-26 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US9994010B2 (en) 2014-01-24 2018-06-12 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US9605168B2 (en) 2014-01-31 2017-03-28 Ceraloc Innovation Ab Digital print with water-based ink
US10737506B2 (en) 2014-01-31 2020-08-11 Ceraloc Innovation Ab Digital print with water-based ink
US11173722B2 (en) 2014-01-31 2021-11-16 Ceraloc Innovation Ab Digital print with water-based ink
US10071563B2 (en) 2014-01-31 2018-09-11 Ceraloc Innovation Ab Digital print with water-based ink
US11186997B2 (en) 2016-03-24 2021-11-30 Valinge Innovation Ab Method for forming a décor on a substrate
EP3498479A1 (fr) * 2017-12-18 2019-06-19 OCE Holding B.V. Procédé d'impression de bandes d'une image sur un substrat
WO2019170456A1 (fr) * 2018-03-09 2019-09-12 Agfa Nv Procédé de fabrication de panneaux décoratifs

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