A method of forming a digital embossing (17) on a surface (2) by bonding hard press particles (67) to a carrier (68). A liquid binder pattern (P) is applied on the carrier by a digital drop application head. Hard press particles (67) are applied on the carrier (68) and the binder pattern such that some hard press particles are bonded to the carrier (68) by the liquid pattern and non-bonded press particles (67) are removed. The carrier (68) with the bonded hard press particles (67) is pressed to the surface (2) and an embossing is formed when the carrier (68) with the hard press particles (67) is removed.

The present invention is directed to a door skin having an exterior surface with an woodgrain pattern formed therein, and an etched plate for use as an embossing plate or with a molded die set, for forming the woodgrain pattern in the door skin. The exterior surface has outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and halftone portions. The halftone portions have spaced protrusions defined by channels, wherein the channels are recessed from the plane of the outer portions.

Pigment based particles in powder form intended to be used as colourants in a digital print formed by applying dry colourants on a surface, bonding a part of the colourants with a binder and removing the non-bonded colourants from the surface. A panel with a surface including a digitally formed print of macro colourants including a particle body and colour pigments attached to the surface of the particle body is also described. The colourants are arranged in patterns with pigments on an upper and lower surface of the particle body.

A method of forming a digital print on a surface (2) by applying powder of dry ink (15) including colourants (7) on the surface, bonding a part of the dry ink (15) powder to the surface (2) by a digital heating print head (80) such that the digital print is formed by the bonded dry ink colourants (7) and removing non-bonded dry ink (15) from the surface (2).

Structures for use in forming products having a wood grain appearance include, for example, a plurality of extruded layers having different colors/shades spirally wound about a longitudinal axis to an outer surface to define the structure. The plurality of extruded layers include varying thicknesses along a spiral length of the plurality of layers and/or portions of the plurality of extruded layers encircling the longitudinal axis include portions disposed at different distances from the longitudinal axis. In some embodiments, the spirally winding includes forming a cylindrical structure, and pressing the cylindrical structure into a cuboid structure having a square or rectangular cross-section across the longitudinal axis and at least a portion of the plurality of extruded layers defining a square or rectangle pattern across the longitudinal axis. Longitudinal portions may be cut from the structures to form the products having a wood grain appearance.

Resin systems and methods for making and using same are provided. The resin system can include a first aqueous resin comprising at least two polymerized monomers and a second aqueous resin comprising at least two polymerized monomers. The first aqueous resin can be present in an amount of about 5 wt % to about 95 wt %, based on the total weight the resin system. The second aqueous resin can be present in an amount of about 5 wt % to about 95 wt %, based on the total weight the resin system. The at least two polymerized monomers of the first and second aqueous resins can be the same monomers.

Pigment based particles in powder form intended to be used as colorants in a digital print formed by applying dry colorants on a surface, bonding a part of the colorants with a binder and removing the non-bonded colorants from the surface. A panel with a surface including a digitally formed print of macro colorants including a particle body and color pigments attached to the surface of the particle body is also described. The colorants are arranged in patterns with pigments on an upper and lower surface of the particle body.

A method and equipment to form a digital print by applying dry colourants on a surface of a panel, bonding a part of the colourants with a binder and removing the non-bonded colourants from the surface. The method of forming a digital print on a surface of a panel includes displacing the panel under a digital drop application head, applying a liquid binder with the digital drop application head on the surface; applying colourants on the liquid binder and the surface; bonding a part of the colourants to the surface with the liquid binder; removing non-bonded colourants from the surface such that a digital print is formed by the bonded colourants; and applying heat and pressure on the panel, the surface and the bonded colorants such that the colourants are permanently bonded to the surface.

A door skin featuring a facing having an exterior surface and an interior surface can be provided. A wood grain pattern portion can be formed in the exterior surface of the facing. The wood grain pattern portion can feature a plurality of grooves formed in the exterior surface of the facing, the grooves are recessed from a first plane of the exterior surface, and tonal portions formed in the exterior surface of the facing. The tonal portions can include at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion can be different from spacing between the second protrusion and the third protrusion.

A method, a panel and equipment to form a digital print by applying dry ink (15), preferably including particles of pigment coated wood fibres (61), on a surface (2), bonding a part of the particles with a liquid blank ink drops (57) and removing the non-bonded particles from the surface (2).