METHOD AND SYSTEM FOR PRODUCING A RELIEF ON A SUBSTRATE

Abstract

A method and system for producing a relief on a substrate (1), the method having the application on the substrate (1) of a coating and a relief product that come into contact with each other and the sublimation of the relief product (3).

Claims

1. A method for producing a relief on a substrate (1), comprising applying on a substrate (1) a coating (2) and a relief product (3) that make contact with each other and carrying out sublimation of the relief product (3) to leave hollows in the coating (2), corresponding to areas previously occupied by the relief product (3) in contact with the coating (2), the hollows determining the relief.

2. The method for producing a relief on a substrate (1) according to claim 1, wherein the coating (2) is applied on the relief product (3).

3. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) is applied on the coating (2).

4. The method for producing a relief on a substrate (1) according to claim 1, further comprising after sublimating the relief product, removing the coating affected by the sublimation of the relief product and/or a residue of relief product.

5. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) is applied by means of digital inkjet printing.

6. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) is applied in coordination with an image on the substrate (1).

7. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) is transparent.

8. The method for producing a relief on a substrate (1) according to claim 1, wherein the coating (2) and/or the relief product (3) is applied in liquid form on the substrate (1).

9. The method for producing a relief on a substrate (1) according to claim 8, wherein the coating (2) and the relief product (3) come into contact with each other when the coating (2) is liquid or partially solidified.

10. The method for producing a relief on a substrate (1) according to claim 1, wherein the coating (2) and/or the relief product (3) are solidified.

11. The method for producing a relief on a substrate (1) according to claim 10, wherein the coating (2) an/or the relief product (3) are at least partially solidified before sublimating the relief product (3).

12. The method for producing a relief on a substrate (1) according to claim 10, wherein the solidification of the coating (2) and/or of the relief product (3) is carried out by curing, by means of electromagnetic radiation or by UV.

13. The method for producing a relief on a substrate (1) according to claim 10, wherein the coating (2) finishes solidifying later than the relief product (3).

14. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product and the coating are applied on successive occasions to obtain a plurality of layers of coating and relief product.

15. The method for producing a relief on a substrate (1) according to claim 1, wherein the sublimation of the relief product (3) is carried out by heating by means of a source of electromagnetic radiation by means of IR, by means of a thermal convection element, by heated air, or by means of a thermal conduction heating element.

16. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) is applied by using a sublimation ink.

17. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product (3) and/or the sublimation ink are miscible in the coating (2).

18. The method for producing a relief on a substrate (1) according to claim 16, wherein the sublimation ink is a dispersion wherein the dispersed portion comprises the relief product (3).

19. The method for producing a relief on a substrate (1) according to claim 1, wherein the relief product comprises sublimatable solid particles.

20. The method for producing a relief on a substrate (1) according to claim 19, wherein the sublimatable solid particles are a size (D50) smaller than or equal to 2000 Å, smaller or equal than 100 Å, or smaller than or equal to 10 Å.

21. The method for producing a relief on a substrate (1) according to claim 16, wherein the relief product (3) has a concentration of sublimation ink when being applied less than or equal to 10% by weight, less than or equal to 1% by weight, or less than or equal to 0.1% by weight.

22. The method for producing a relief on a substrate (1) according to claim 16, wherein the sublimation ink comprises an electromagnetic radiation absorbing agent, configured to substantially absorb electromagnetic radiation energy irradiated in a determined wavelength, electromagnetic radiation for curing the coating (2) and/or the relief product (3), transforming said energy into heat.

23. The method for producing a relief on a substrate (1) according to claim 22, wherein the electromagnetic radiation absorbing agent is of UV absorbing agent selected from the group consisting of benzophenones, benzotriazoles, triazines, oxanilides and cyanoacrylates.

24. The method for producing a relief on a substrate (1) according to claim 16, wherein the sublimation ink comprises an exothermic chemical reaction promoting agent, configured to react in the coating (2) by releasing heat.

25. The method for producing a relief on a substrate (1) according to claim 16, wherein the sublimation ink comprises an odoriferous agent configured to impart odour to the coating (2) when activated by heating.

26. A system for producing a relief on a substrate (1), which comprises means for applying (70) a coating on the substrate (1), means for applying (40) a relief product (3), means for sublimating (20) the relief product (3), and means for controlling the means for applying the coating (2), the means for applying the relief product (3) and the means for sublimating the relief product (3), configured to carry out a method according to claim 1.

27. The system for producing a relief on a substrate (1), according to claim 26, wherein the means for sublimating (20) the relief product (3) comprise at least one electromagnetic radiation heating lamp (21), at least one convection heating element, and/or at least one thermal conduction heating element (22).

28. The system for producing a relief on a substrate (1), according to claim 26, comprising a sublimation material reception strip (90) that faces the coating (2) so that, when the relief product (3) is sublimated, sublimation material formed by coating affected by the sublimation of the relief product (3) and/or a residue of the relief product (3) is projected onto the reception strip.

29. The system for producing a relief on a substrate (1), according to claim 27, comprising means for cleaning (50) a surface of the thermal conduction heating element (22) or of the reception strip (90) on which the sublimation material is projected, comprising a scraping blade (51) for scraping said surface or strip.

30. The system for producing a relief on a substrate (1), according to claim 27, comprising means for removing (30) from the coating (2) sublimation material formed by coating affected by the sublimation of the relief product (3) and/or a residue of relief product (3), in the form of at least one brush, at least one vacuum (31) and/or at least one blower.

31. The system for producing a relief on a substrate (1), according to claim 26, comprising means for extracting (80) gas from the sublimation of the relief product (3), in the form of a gas extraction hood (81), and/or solidification means (10) for at least partially solidifying the coating (2) and/or the relief product (3), and/or substrate transport means (60) for transporting the substrate (1) while carrying out the method.

Description

DESCRIPTION OF THE FIGURES

[0048] The following figures are included that serve to illustrate different practical embodiments of the invention that are described below by way of example but not limitation.

[0049] FIG. 1 schematically shows the cross section of a substrate on which a relief is obtained, in steps (A) to (C) according to a first embodiment of the method or system of the invention.

[0050] FIG. 2 schematically shows the cross section of a substrate on which a relief is obtained, in steps (D) to (G) according to a first variant of the first embodiment of the method or system of the invention.

[0051] FIG. 3 schematically shows the cross section of a substrate on which a relief is obtained, in steps (D) to (G) according to a second variant of the first embodiment of the method or system of the invention.

[0052] FIG. 4 schematically shows the cross section of a substrate on which a relief is obtained, in steps (A) to (C) according to a second embodiment of the method or system of the invention.

[0053] FIG. 5 schematically shows the cross section of a substrate on which a relief is obtained, in steps (D) to (G) according to a first variant of the second embodiment of the method or system of the invention.

[0054] FIG. 6 schematically shows the cross section of a substrate on which a relief is obtained, in steps (D) to (G) according to a second variant of the second embodiment of the method or system of the invention.

[0055] FIG. 7 shows an overview of a first exemplary embodiment of a method and system for producing a relief on a substrate according to the invention, wherein the substrate is in the form of a panel.

[0056] FIG. 8 shows an overview of a second exemplary embodiment of a method and system for producing a relief on a substrate according to the invention, wherein the substrate is in the form of a continuous sheet.

[0057] FIG. 9 shows a detailed view of a variant of a sublimation step or station of the method and system according to the invention.

[0058] FIG. 10 shows a detailed view of an additional variant of a sublimation step or station of the method and system according to the invention.

[0059] FIG. 11 shows a detailed view of an additional variant of sublimation step or station of the method and system according to the invention.

[0060] FIG. 12 shows a detailed view of an additional variant of sublimation step or station of the method and system according to the invention.

[0061] FIG. 13 shows a detailed view of an additional variant of sublimation step or station of the method and system according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0062] The substrates (1) can be configured by way of panels or profiles. The material of the substrates (1) can be selected, for example, from wood (chipboard, medium-density fibreboard “MDF”, high-density fibreboard “HDF” or plywood), plastic (PVC), cellulose-based materials (paper or cardboard) or metal.

[0063] The coating (2) can be applied in liquid state by any method for applying liquid products, for example, by roller, sprinkling, spraying or inkjet printing. The material of the coating (2) can be selected, for example, between varnish or polymerisable resin.

[0064] In the embodiments of the invention that are shown in the figures and described in detail below, the relief product (3) is digitally inkjet-printed, being applied in the form of droplets of sublimation ink.

[0065] According to a first embodiment of the invention shown in FIGS. 1 to 3, the starting point is a substrate (A) on which a coating (2) is applied (B), the relief product (3) being applied (C) on the coating (2).

[0066] According to a second embodiment of the invention shown in FIGS. 4 to 6, the starting point is a substrate (A) on which a relief product (3) is applied (B, C) directly on the substrate (1).

[0067] With reference to FIG. 2, in a first variant of the first embodiment shown in FIGS. 1 to 3, there is an impact, immiscibility or displacement of the droplets of the relief product (3) in the coating (2) to produce the relief.

[0068] With reference to FIG. 3, in a second variant of the first embodiment shown in FIGS. 1 to 3, there is a mixture or dilution of the droplets of relief product (3) in the coating (2) to produce the relief.

[0069] With reference to FIG. 5, in a first variant of the second embodiment shown in FIGS. 4 to 6, there is an impact, immiscibility or displacement of the droplets of the relief product (3) in the coating (2) to produce the relief.

[0070] With reference to FIG. 6, in a second variant of the second embodiment shown in FIGS. 4 to 6, there is a mixture or dilution of the droplets of relief product (3) in the coating (2) to produce the relief.

[0071] After the coating (2) comes into contact (D) with the relief product (3), the coating (2) and the relief product (3) are cured (E), together or separately, obtaining the solidification of at least the relief product (3). Conventional curing means (10) can be used for curing, such as heating lamps or electromagnetic radiation emission, for example of UV, IR or electron emission light.

[0072] Once the relief product (3) has solidified, it is sublimated (F). Conventional sublimation means (20) can be used for sublimation (F), such as by means of heating, in particular, by means of hot air or by means of heating lamps such as, for example, IR heating lamps. It is also envisaged that the sublimation (F) can be performed by reacting the relief product (3) with a sublimation activation product, for example, by applying said sublimation activation product on the relief product (3). The sublimation (F) can be simultaneously carried out, for example, with the solidification of the coating.

[0073] Finally, means for removing material (30) can be used to remove (G) coating material in the areas affected by sublimation. These means (30) can be, for example, mechanical means such as brushing or vacuuming, or chemical means such as washing or rinsing of said areas.

[0074] FIG. 7 shows a process line according to the first preferred exemplary embodiment of the invention to obtain a relief (7) on a substrate (1) in the form of a panel. The substrate (1) advances through the different steps or stations being transported (60) by means of a conveyor belt (63).

[0075] In a first step or station of the process line, a liquid coating (2) is applied on the substrate (1), coating that is made of a UV-curable acrylic, by means of roller (70), using an applicator roller (71) and a dosing roller (72) in a manner known per se. In a subsequent step or station, the relief product (3) is applied on the coating (2) by means of inkjet digital printing (40) using a sublimation ink, which contains the relief product (3) dispersed in a UV-curable acrylic liquid, through injection heads (41) of the sublimation ink.

[0076] In this exemplary embodiment, the sublimation ink is applied on the coating (2) while this is still liquid, which facilitates the penetration of the sublimation ink, and therefore of the relief product (3) into the coating (2). In a subsequent step or station of this first exemplary embodiment, the set of the coating (2) and sublimation ink that have been applied partially solidifies (10), being partially cured by means of a UV radiation lamp (11).

[0077] Then, in the subsequent step or station, the sublimation (20) of the product of the relief product (3) is carried out. To do this, heat is transferred to the relief product (3) by thermal conduction (22) by means of a heated roller (221) which rolls on the coating (2). This rolling is preferably synchronised with the advance of the substrate (1) along the process line, so that the heated roller (221) rolls substantially without sliding on the coating (2) for sublimating the relief product (3).

[0078] During the sublimation (20), sublimation material formed by coating affected by the sublimation of the relief product (3) and/or a residue of relief product (3) is projected on the outer surface of the heated roller (221). This sublimation material is cleaned (50) from the outer surface of the heated roller (221) by means of a scraping blade (51) for scraping the same. The gas from the sublimation of the relief product (3) is extracted (80) by means of an extraction hood (81).

[0079] Then, in a final step or station of this first exemplary embodiment, the coating finishes solidifying (10), being cured by means of a UV radiation lamp (12). Afterwards, a step for removing (30) excess material, such as coating affected by the sublimation of the relief product and/or a residue of relief product can be applied, for example, by means of brushing.

[0080] FIG. 8 shows a process line according to the second preferred exemplary embodiment of the invention to obtain a relief (7) on a substrate (1), wherein unlike the first exemplary embodiment, the substrate (1) is in the form of a continuous sheet. The sheet is fed continuously from a feed coil (5) to pass through the different stations or steps of the line until a collection coil (6), wherein the sheet is collected with the relief (7) produced on the substrate (1) for distribution or subsequent processing thereof. The sheet moves along the line by means of guide means, for example, guide rollers, in a manner known per se.

[0081] As FIG. 8 shows, the different steps or stations of this second exemplary embodiment are arranged or configured in a similar manner to the stations or steps of the first exemplary embodiment. In the step or station of application of the coating by means of roller (70) a counter roller (71′) of the applicator roller of the coating is incorporated, for positioning the substrate (1) by means of a counterpressure with said roller. Likewise, in the step or station of sublimation (20) a counter roller (221′) of a heated roller is incorporated for positioning the substrate (1) by means of a counterpressure with said heated roller.

[0082] FIG. 9 shows a variant of the sublimation step or station (20), represented for the first exemplary embodiment but which can be similarly applicable to the second exemplary embodiment. In this variant embodiment, unlike the examples shown in FIGS. 7 and 8, during sublimation (20) the sublimation material formed by coating affected by the sublimation of the relief product (3) and/or a residue of relief product (3), instead of directly on the surface of the heated roller (221), is projected onto a sublimation material reception element, in the form of a reception strip (90). The reception strip (90) is fed from a feeding coil (93), being guided as it passes between the heated roller and the coating, until a collection coil (94), in which said sublimation material already deposited is collected for the external processing, recycling or removal thereof.

[0083] FIG. 9 also shows other constructive details of the heated roller (221) system. The heated roller (221) is able to move vertically by means of a vertical movement actuator (224) in an adjustable manner to move closer to the coating (2) with the relief product (3) applied therein, in cooperation with the counter roller (221′), for positioning the substrate (1) by exerting a counterpressure with said roller. The heated roller (221) is provided with a rotation actuator (223), to cause the heated roller (221) and the reception strip (90) to rotate on the coating (2) in a manner synchronised with the forward movement of the substrate (1), preferably substantially producing a rolling without sliding, at the same time that the advance of the reception strip (90) trapped between the heated roller (221) and the coating (2) occurs as the sublimation material is transferred to the reception strip (90). For transporting (60) the substrate (1) in the advance thereof, a conveyor belt (63) has been provided that moves guided by guide rollers (61, 62) and driven by means of a rotation actuator (64) which in the represented example acts to rotate one of the guide rollers (62).

[0084] FIG. 10 shows another variant of the sublimation step or station (20), equally represented for the first exemplary embodiment but which can be similarly applied to the second exemplary embodiment. In this variant embodiment, unlike the variant shown in FIG. 9, the reception strip (90) is continuously fed in a closed circuit being guided by means of guide rollers (91). The guide rollers (91) can move vertically to adjust the position of the guide roller (91) facing the coating (2) by means of a vertical movement actuator (95), enabling the substrate (1) to advance between this guide roller (91) and a counter roller (91′). The reception strip (90) is moved by means of a rotation actuator (92) that causes, for example, said guide roller (91) facing the coating (2) to rotate.

[0085] In the same manner as with the variant shown in FIG. 9, in the variant of FIG. 10 the sublimation material is transferred to the reception strip (90), however, in this variant, the reception strip (90) is refed once it has been cleaned (50) of sublimation material previously deposited on the same. Said cleaning (50) can be carried out, for example, as FIG. 10 shows by means of a scraping blade (51) for scraping the reception strip (90), i.e., the contact surface of the reception strip (90) with the coating (2) when the sublimation material is transferred to the same.

[0086] FIG. 10 also shows sublimation means that are alternative or complementary to the heated roller (221) shown in the variants described above. In this variant, the heating to produce the sublimation (20) can be carried out by thermal convection in the area of the guide roller (91) which faces the coating (2) by means of the strip of the reception strip (90). Particularly, the strip (90) can be configured in a material, for example, metal, which facilitates thermal conduction in the coating (2) locally and/or be heated.

[0087] FIG. 11 shows another variant of the sublimation step or station (20), equally represented for the first exemplary embodiment but which can be similarly applied to the second exemplary embodiment. In this variant embodiment, unlike the variant shown in FIG. 10, the sublimation is carried out by means of radiation heating (21). The heating can be carried out directly towards the coating (2), through a reception strip (90) of sublimation material transparent to the passage of the radiation, or indirectly by heating the reception strip (90).

[0088] As can be observed in FIG. 11, the heating (21) is carried out between two guide rollers (91) which are facing the coating (2) in two consecutive positions such that the reception strip (90) continuously remains in contact with the coating (2) between said two positions. This makes it possible to provide a smoothing of the surface of the coating (2) at the same time as the heating (21). Alternatively or complementarily to the heating (21), a partial solidification (10) can be carried out by means of a UV radiation lamp (211) through a reception strip (90) transparent to said radiation. In this manner, a more efficient curing can be achieved, as the amount of air present between the strip (90) and the coating (2) in said area is reduced.

[0089] FIG. 12 shows another variant of the sublimation step or station (20), represented for the first exemplary embodiment but which can be similarly applied to the second exemplary embodiment. In this variant embodiment, unlike the variants described above, the heating of the coating to carry out the sublimation (20) is carried out by means of a thermal conduction element (22) in the form of a heated plate (222). The heated plate (222) can move vertically by means of vertical movement actuators (225) so that, to heat the coating (2) with the relief product (3) and produce the sublimation thereof, the plate (222) faces the coating (2) until making contact with the same, the substrate (1) remaining between the plate (222) and counter rollers (222′). The cleaning (50) of the sublimation material transferred to the plate (222) is carried out by means of the scraping blade (51) that can move horizontally for sweeping said sublimation material, being deposited in a collection tray (52) of said removed material.

[0090] FIG. 13 shows another variant of the sublimation step or station (20), represented for the first exemplary embodiment but which can be similarly applied to the second exemplary embodiment. In this variant embodiment, unlike the variant shown in FIG. 12, there is a reception strip (90) of sublimation material that is arranged between the plate (222) and the coating (2) to receive the sublimation material from the coating (2). The reception strip (90) is cleaned (50) of said sublimation material by means of a scraping blade (51).

[0091] The invention is not limited to the variants represented, but it includes all the variants, modifications and combinations comprised in the scope of the attached claims.

[0092] Thus, for example, according to the invention the heating to produce the sublimation (20) can be carried out in a single step or station or in several steps or stations that are successive, consecutive with each other or alternated with other steps or stations of the method. In this sense, it is envisaged that a progressive heating of the coating (2) can be carried out before the sublimation starts, for example, by means of a plurality of conduction heating elements (22), such as heated rollers (221).

Examples of Practical Embodiments

[0093] By way of example, Caffeine or Camphor have been used as sublimatable products to obtain a practical embodiment sample with each one of them according to the invention.

[0094] We started from a sublimatable product in the form of commercially available powders, these powders have a variety of particle sizes and can even have caked or agglomerated portions due to humidity. This powder was ground to obtain a sublimatable product powder with a particle size (D50) of 2000 Å. Then, said ground sublimatable product was dispersed in a dispersant consisting of an acrylic liquid partially inhibited to UV curing to form a colloidal solution with a sublimatable product concentration of approximately 5% by weight of the sublimation ink, obtaining a sublimation ink that can be used by means of inkjet printing.

[0095] The sublimation ink was printed by inkjet, according to a digital template of a relief. Said digital printing was carried out on a liquid coating, of UV-curable acrylic varnish, previously applied on a wood substrate. The printing was carried out by means of printing heads marketed under the trademark Seiko 1536RC (heads with recirculation) as well as with printing heads marketed under the same trademark Seiko 508GS (without recirculation).

[0096] Once the sublimation ink was applied, the sample with the applied coating and the relief product was subjected to UV radiation by means of electric arc discharge lamps until partially curing the coating, until having a maximum curing degree of approximately 40% (with respect to the irradiated energy that would be required to completely cure the coating). Next, the sample was heated by subjecting it to an IR radiation by means of IR lamps, until reaching a coating temperature of approximately 160° C. for the samples wherein the sublimatable product was Caffeine or a coating temperature of approximately 150° C. for the samples wherein the sublimatable product was Camphor.

[0097] By means of said heating said sublimatable product was sublimated, producing a weakening in the coating in coating areas that determine the relief to be obtained (cavernous areas as a result of the evacuation of gas from the sublimation). Next, the sample was subjected to a final curing for the total solidification thereof.

[0098] Finally, brushing was applied on the entire surface of the coating to remove said coating areas that have been weakened by the effect of the sublimation, the corresponding hollows to said areas being exposed once the material is removed from the inside thereof, consisting of coating affected by the sublimation of the sublimatable product and/or a residue of applied sublimation ink, resulting in the relief.

LIST OF REFERENCE SIGNS

[0099] 1 substrate [0100] 2 coating [0101] 3 relief product [0102] 4 relief hollow [0103] 5 substrate feed coil in the form of continuous sheet [0104] 6 substrate collection coil in the form of continuous sheet [0105] 7 relief obtained [0106] 10 solidification means [0107] 11 initial curing UV lamp [0108] 12 final curing UV lamp [0109] 20 sublimation means [0110] 21 electromagnetic radiation heating lamp [0111] 211 UV heating lamp [0112] 22 thermal conduction heating element [0113] 30 means for removing coating material [0114] 31 vacuum for removing coating material [0115] 40 inkjet digital printing means [0116] 41 inkjet printing head [0117] 50 means for cleaning sublimation material [0118] 51 scraping blade [0119] 52 collection tray for sublimation material [0120] 60 substrate transport means [0121] 61 first guide roller for conveyor belt [0122] 62 second guide roller for conveyor belt [0123] 63 substrate conveyor belt [0124] 64 rotation actuator of guide roller for conveyor belt [0125] 70 application means of liquid coating [0126] 71 applicator roller of liquid coating [0127] 71′ counter roller of applicator roller [0128] 72 dosing roller of liquid coating [0129] 80 means for extracting gas from sublimation [0130] 81 extraction hood of gas from sublimation [0131] 90 reception strip of sublimation material [0132] 91 guide roller of reception strip of sublimation material [0133] 91′ counter roller of guide roller of reception strip [0134] 92 rotation actuator of guide roller of reception strip of sublimation material [0135] 93 feeding coil of reception strip of sublimation material [0136] 94 collection coil of reception strip of sublimation material [0137] 95 vertical movement actuator of guide roller [0138] 221 thermal conduction heating roller [0139] 221′ counter roller of heating roller [0140] 222 thermal conduction heating plate [0141] 222′ counter roller of thermal conduction heating plate [0142] 223 rotation actuator of heating roller [0143] 224 vertical movement actuator of heating roller [0144] 225 vertical movement actuator of heating plate