DIGITAL EMBOSSING OF DECORATIVE SURFACE COVERINGS

Abstract

A method for producing a decorative surface covering comprises providing a structural core (10), including one or more core layers (12), the structural core carrying a decor layer (25) representing a two-dimensional decor, and generating a three-dimensional surface relief (30) by digitally embossing, in register with the two-dimensional decor. The three-dimensional surface relief is generated at a distance of at least 0.1 mm from the decor layer by applying a transparent or at least translucent spacer layer (28) against the decor layer, the spacer layer having a thickness that remains unmodified by the digital embossing and that corresponds to the distance. The three-dimensional surface relief is generated in one or more coating layers (30a, 30b) on a side of the spacer layer facing away from the decor layer after application of the spacer layer against the decor layer.

Claims

1. A method for producing a decorative surface covering comprising: providing a structural core, including one or more core layers, the structural core carrying a dcor layer representing a two-dimensional dcor; generating a three-dimensional surface relief by digitally embossing, in register with the two-dimensional dcor, wherein the three-dimensional surface relief is generated at a distance of at least 0.1 mm from the dcor layer by applying a transparent or at least translucent spacer layer against the dcor layer, the spacer layer having a thickness that remains unmodified by the digital embossing and that corresponds to said distance, wherein the three-dimensional surface relief is generated in one or more coating layers on a side of the spacer layer facing away from the dcor layer after application of the spacer layer against the dcor layer.

2. The method as claimed in claim 1, wherein the thickness of the spacer layer and said distance amount to 0.15 mm or more.

3. The method as claimed in claim 1, wherein the spacer layer is laminated with the structural core carrying the dcor layer prior to three-dimensional surface relief generation.

4. The method as claimed in claim 1, wherein the spacer layer is produced, at least in part, by coating the structural core with a plastisol, which is thereafter solidified.

5. The method as claimed in claim 1, wherein the spacer layer is attached to the structural core carrying the dcor layer with at least one of hot melt glue, heat-sensitive glue and/or pressure-sensitive glue.

6. The method as claimed in claim 1, wherein the spacer layer comprises a polyethylene terephthalate polymer, a polyethylene polymer, a polypropylene polymer, or a polyvinyl chloride polymer.

7. The method as claimed in claim 1, wherein the structural core comprises a printable surface and wherein the method includes digitally printing the dcor layer onto the printable surface of the structural core prior to application of the spacer layer against the dcor layer.

8. The method as claimed in claim 1, wherein individual slabs of the structural core are provided and wherein the digital embossing is carried out slab by slab, registration of the three-dimensional surface relief with the two-dimensional dcor being effected by taking registration marks or one or more borders of the slabs or both registration marks and one or more borders of the slabs as references.

9. The method as claimed in claim 1, wherein the digital embossing includes: applying a coating layer on the side of the spacer layer facing away from the dcor layer, providing a negative of at least part of the three-dimensional surface relief by digital 3D printing of an embossing tool, pressing the 3D-printed embossing tool against the coating layer so as to form therein at least said part of the three-dimensional surface relief, and fixing the three-dimensional surface relief in the coating layer.

10. The method as claimed in claim 1, wherein the digital embossing includes: applying a thickness-modulated coating on the side of the spacer layer facing away from the dcor layer by digital additive 3D printing.

11. The method as claimed in claim 1, wherein the digital embossing includes: applying a coating layer on the side of the spacer layer facing away from the dcor layer, applying an inhibiting agent in a pattern onto, into or below the coating layer by digital printing, solidifying the coating layer, the inhibiting agent inhibiting the solidification in said pattern, and removing unsolidified parts of the coating layer.

12. The method as claimed in claim 1, wherein the digital embossing includes: applying a coating layer on the side of the spacer layer facing away from the dcor layer, applying a coating-repellent agent, into or below the coating layer by digital printing so as to create in said coating layer a pattern. solidifying the coating layer, and removing the coating-repellent agent.

13. The method as claimed in claim 1, further including: generating a three-dimensional surface relief file by calculating a three-dimensional surface relief based on a determined dcor type, lineal and areal features of the two-dimensional dcor, and said distance, said three-dimensional surface relief file defining at least one of raised and/of lowered areas with respect to a reference level, the reference level being coincident with the side of the spacer layer facing away from the dcor layer or separated therefrom by a known spacing; providing the 3D surface texture file to a digital embossing equipment carrying out the digital embossing, the digital embossing equipment interpreting the 3D surface texture file and carrying out the digitally embossing in accordance with the 3D surface texture file.

14. A method for producing a decorative surface covering, the decorative surface covering comprising flooring or wallcovering, the method comprising: providing a structural core, including one or more core layers, the structural core comprising a printable surface; digitally printing a dcor layer onto the printable surface of the structural core, the dcor layer representing a two-dimensional dcor applying a transparent or at least translucent spacer layer against the dcor layer, after digital printing of the digitally printing of the dcor layer, the spacer layer having a thickness of at least 0.1 mm; generating a three-dimensional surface relief by digitally embossing, in register with the two-dimensional dcor, wherein the three-dimensional surface relief is generated at a distance of at least 0.1 mm from the dcor layer by maintaining the thickness of the spacer layer unmodified by the digital embossing, wherein the three-dimensional surface relief is generated in one or more coating layers on a side of the spacer layer facing away from the dcor layer after application of the spacer layer against the dcor layer; wherein the digital embossing includes: applying a coating layer on the side of the spacer layer facing away from the dcor layer, applying an inhibiting agent in a pattern onto, into or below the coating layer by digital printing, solidifying the coating layer, the inhibiting agent inhibiting the solidification in said pattern, and removing unsolidified parts of the coating layer.

15. The method as claimed in claim 14, wherein the thickness of the spacer layer amounts to 0.15 mm or more.

16. The method as claimed in claim 14, wherein the spacer layer is laminated with the structural core carrying the dcor layer prior to three-dimensional surface relief generation, the spacer layer being attached to the structural core carrying the dcor layer with at least one of hot melt glue, heat-sensitive glue and pressure-sensitive glue.

17. The method as claimed in claim 14, wherein the spacer layer is produced, at least in part, by coating the structural core with a plastisol, which is thereafter solidified.

18. The method as claimed in claim 14, wherein the spacer layer comprises a polyethylene terephthalate polymer, a polyethylene polymer, a polypropylene polymer, or a polyvinyl chloride polymer.

19. The method as claimed in claim 14, wherein individual slabs of the structural core are provided and wherein the digital embossing is carried out slab by slab, registration of the three-dimensional surface relief with the two-dimensional dcor being effected by taking registration marks or one or more borders of the slabs or both registration marks and one or more borders of the slabs as references.

20. The method as claimed in claim 14, further including: generating a three-dimensional surface relief file by calculating a three-dimensional surface relief based on a determined dcor type, lineal and areal features of the two-dimensional dcor, and said distance, said three-dimensional surface relief file defining at least one of raised and lowered areas with respect to a reference level, the reference level being coincident with the side of the spacer layer facing away from the dcor layer or separated therefrom by a known spacing; providing the 3D surface texture file to a digital embossing equipment carrying out the digital embossing, the digital embossing equipment interpreting the 3D surface texture file and carrying out the digitally embossing in accordance with the 3D surface texture file.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] By way of example, preferred, non-limiting embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which:

[0051] The accompanying drawings illustrate several aspects of the present invention and, together with the detailed description, serve to explain the principles thereof. In the drawings:

[0052] FIG. 1: is a schematic illustration of a production line for implementing a method of producing a decorative surface covering according to a first embodiment of the invention;

[0053] FIG. 2: is a schematic illustration of a production line for implementing a method of producing a decorative surface covering according to a second embodiment of the invention;

[0054] FIG. 3: is a schematic illustration of a production line for implementing a method of producing a decorative surface covering according to a third embodiment of the invention;

[0055] FIG. 4: illustrates a possible way of applying a relief on a decorative surface covering;

[0056] FIG. 5: is a schematic illustration of a production line for implementing a method of producing a surface floor covering according to a fourth embodiment of the invention.

DETAILED DESCRIPTION OF ONE OR MORE PREFERRED EMBODIMENTS

[0057] It will be understood that the following description and the drawings to which it refers describe by way of example several embodiments of the proposed invention for illustration purposes. This description of preferred embodiments shall not limit the scope, nature or spirit of the claimed subject matter. The skilled person will appreciate that features of the different embodiments may be combined into further embodiments without departing from the scope of the present invention.

[0058] FIG. 1 illustrates a first embodiment of the proposed method for producing a decorative surface covering. A multilayer printing substrate is provided in the form of a structural core (also: core structure) 10 comprising a support layer 12 coextruded with a printable layer (hereinafter: dcor-carrying layer) 14. Thermoplastic melt streams 16, 18 are guided from respective extruders 20, 22 to the co-extrusion die 24, where the core structure 10 is formed. The support layer 12 is illustrated in this example as a monolayer for simplicity and the skilled person will understand that it could be replaced by a multilayer structure, provided that a suitable multi-manifold die is used instead of a two-manifold die.

[0059] Downstream of the co-extrusion die 24, a two-dimensional dcor 25 is digitally printed on the dcor carrying layer 14 of the core structure 10 using digital printing equipment 26, which includes, preferably, an industrial printer.

[0060] The digital printing equipment preferably comprises printheads that project ink droplets onto the dcor-carrying layer 14 in a very precise manner, in terms of position and volume of the droplets.

[0061] Digital printing equipment 26 preferably comprises a Single-Pass industrial printer, which uses several printheads aligned side by side in several rows that cover the width of printing substrate. Each row of printhead may prints one or more colours. During the printing process, the printing substrate proceeds in the machine direction under the printheads. Digital printing equipment 26 may be custom-made for the application in accordance with the requirements in terms of capacity and print quality. Digital printing equipment 26 could use thermal printhead technology, wherein a current pulse passing through a heating element vaporizes a tiny quantity of ink in a chamber so as to form a bubble, and this bubble propels an ink droplet through the printhead nozzle onto the printing substrate. Digital printing equipment 26 could also use piezoelectric printheads, wherein a piezoelectric element, on application of a voltage, generates a pressure pulse that drives an ink droplet through the nozzle. The ink is chosen in accordance with the printhead technology, the printing substrate, the subsequent processing steps as well as quality and price constraints.

[0062] Various types of ink could be used in implementations of the method. Inks typically comprise one or more colorants, a binder that bonds the colorants to the surface and a carrier liquid. Colorants comprise dyes or pigments or a combination of both. Pigments are solid colorant particles that are suspended or dispersed throughout the carrier liquid. Pigment-based inks may be more lightstable and more fade-resistant than dye-based inks. Furthermore, dye-based inks often comprise organic solvents which may lead to higher VOC emissions than pigment-based inks, especially when water is the carrier liquid of the latter. Carrier liquids may include solvents, oil(s), water and polymeric resins. For certain surface coverings, radiation-curable inks may be considered as particularly advantageous.

[0063] The printing equipment 26 may comprise a drying or curing stage (not shown in FIG. 1), wherein the printed dcor 25 is solidified and bonded to the dcor-carrying layer 14. Such drying or curing stage could comprise one or more heaters and/or one or more blowers and/or one or more radiation sources, depending of the type of ink used by the printing equipment 26. Drying/curing prior to application of the spacer layer 28 may be particularly recommended if the ink includes non-reactive solvent(s) or carrier(s), which can no longer be efficiently eliminated or reacted after the printed dcor 25 has become sandwiched between its substrate and the spacer layer.

[0064] After application of the printed dcor, the structural core is contacted with the spacer layer 28. The spacer layer 28 is transparent (or at least translucent) and could be applied to the core structure by hot lamination. If hot lamination, typically taking place at temperatures above 150 C., is used, the inks selected in the preceding dcor printing step are selected such that they can withstand the high temperatures of the hot lamination. As an alternative to hot lamination, a cold lamination technique could be employed, using a pressure-sensitive adhesive, or a radiation-curable adhesive. The lamination could in this case be carried out at ambient temperaturewithout excluding that the adhesive heats up under pressure or during the curing when the reactions induced by the radiation are exothermic. This implies that the constraints on the composition of the inks and the spacer layer could be somewhat relaxed on certain aspects if the method of the invention is used: for instance, the spacer layer could be one free from plasticizer or one containing plasticizer.

[0065] An electron-beam-curable polyurethane (PU) and/or acrylate composition, preferably free (or at least substantially free) from any photoinitiator, could be used as a radiation-curable adhesive. The core structure 10 and the spacer layer 28 could be attached to each other by electron-beam curing the adhesive between them. It is not excluded that the inks used for the dcor layer 25 may serve as adhesive for the purpose of attaching the spacer layer 28 to the structural core 10. Electron-beam curing would be carried out with an electron beam curing machine. Upon curing, the adhesive takes the role of a tie layer firmly anchored to both the spacer layer 28 and the structural core 10.

[0066] After application of the spacer layer 28 on the dcor layer 25, a digital embossing step is carried out. It will be understood that different digital embossing techniques are contemplated. Although the illustrated embodiments are preferred embodiments of the invention, digital embossing techniques could be exchanged between them. In the embodiment illustrated in FIG. 1, digital embossing is implemented as digital 3D (layer-by-layer) printing of a relief 30 on top of the spacer layer 28. To print the relief 30, a transparent or at least translucent radiation-curable (e.g. UV- or electron-beam-curable) composition, compatible with the spacer layer 28 is preferably used. In the illustrated embodiment, the relief 30 is built up from multiple individual printed topcoat layers 30a, 30b, applied one after the other, in register with the previously printed dcor 25. In the illustrative example of FIG. 1, first 30a and second 30b layers of a polyurethane topcoat are printed, one after the other, on the spacer layer 28. The 3D printing is carried out using digital printers 32 and 34. After a printing stage, the newly deposited layer(s) of topcoat may be cured or precured in order to prepare these layer(s) for the deposition of further layer(s) of topcoat thereon. In the illustrated embodiment, intermediate curing of the topcoat layer 30a is effected with (radiation-) curing machine 33 located downstream of printer 32 and the final curing is effected with (radiation-) curing machine 35 located downstream of printer 34. In case of a radiation-curable topcoat, the radiation dose applied during the final curing is chosen such that complete curing of all topcoat layers 30a, 30b is achieved. Although FIG. 1 does not show it, the topcoat may comprise one or more continuous layers, so as to completely seal off the underlying spacer layer 30 (and any intermediary topcoat layers). That remark is also valid for the embodiments described further below.

[0067] The printing of the topcoat layers 30a, 30b is carried out in register with the two-dimensional dcor 25. To achieve this, registration marks can be applied on the printing substrate when the two-dimensional dcor 25 is printed. These registration marks can then be used in the production stages downstream, in particular in the digital embossing stage.

[0068] FIG. 2 illustrates a second embodiment of the proposed method for producing a decorative surface covering, which differs from the previously discussed embodiment by the way the structural core is produced. In the example of FIG. 2, a support layer 212 is provided with a primer layer 236 applied on top thereof by a primer application stage. The support layer 212 and the primer layer 236 together form a structural core 210 capable of receiving a two-dimensional dcor 225.

[0069] The primer application stage may comprise a coating apparatus or, as illustrated, a printer 237 and a curing apparatus 238. The printer 237 may be a digital printer but any other printing technique suitable for homogeneously applying the primer layer 236 could be used. When the primer layer 236 has been applied, it is preferably cured using a curing apparatus 238 that uses a curing technique (e.g. heating, radiation-curing) that is compatible with the primer composition employed.

[0070] Downstream of curing apparatus 238, the two-dimensional dcor 225 is digitally printed on the structural core 210 using digital printing equipment 226.

[0071] After the printing of the dcor 225, the structural core 210 is laminated with the spacer layer 228, and after application of the spacer layer 228 on the dcor layer 225, a digital embossing step is carried out so as to generate a three-dimensional relief 230 in register with the dcor 225. These steps may be carried out as described previously for the embodiment of FIG. 1.

[0072] FIG. 3 illustrates a third embodiment of the proposed method for producing a decorative surface covering, which differs from the previously discussed embodiments only by the way the structural core is produced. In the example of FIG. 3, a structural core 310 is provided by applying a primer layer 336 on a support layer 312. The primer is applied in liquid state (e.g. as a plastisol) by guiding the support layer 312 through a bath 336 of primer liquid, which is thereafter solidified with drying/heating device 338.

[0073] The two-dimensional dcor 225 is digitally printed on the structural core 310 using digital printing equipment 326.

[0074] After the printing of the dcor 325, the structural core 310 is laminated with the spacer layer 328, and after application of the spacer layer 328 on the dcor layer 325, a digital embossing step is carried out so as to generate a three-dimensional relief 330 in register with the dcor 325. These steps may be carried out as described previously for the embodiment of FIG. 1.

[0075] The support layer 212, 312 is illustrated in FIGS. 2 and 3 as a monolayer provided by an extruder. It will be appreciated that the support layer could be a multilayer structure, provided that an appropriate extrusion system is used.

[0076] FIG. 4 illustrates the digital embossing of a relief 430 on top of the spacer layer 428 using a different technique than in the previously described embodiments. The relief 430 is built up from multiple individual print layers, applied in register one after the other. In FIG. 4, the spacer layer 428 is already present on the structural core 410 that carries a two-dimensional dcor 425.

[0077] The digital embossing-in-register comprises, as a first step, application of a mask pattern 440 by digital printing, in register with the dcor 425, a coating repellent agent or a solidification-inhibiting agent 441. A first topcoat layer 430a is then applied. Application of the topcoat layer 430a may also be done by digital printing. Alternative coating techniques are possible.

[0078] When the composition of the mask pattern is a coating repellent agent, the combination of coating repellent agent and topcoat material is selected such that the coating repellent agent repels the topcoat material and prevents the topcoat material from entering (or remaining in) the zones covered with the mask pattern. When the composition of the mask pattern is an solidification-inhibiting agent, the combination of solidification-inhibiting agent and topcoat material is selected such that the solidification-inhibiting agent delays or prevents solidification of the topcoat material in the zones covered with the mask pattern. The first layer of topcoat 430a is thereafter solidified (e.g. cured, fused and/or dried) using a solidification apparatus 444.

[0079] Cleaning equipment 446 thereafter removes the mask pattern and/or unsolidified residues of the first topcoat material. In the illustrated example, cleaning equipment 446 includes a brush 447, which loosens the mask pattern/residues by mechanical friction, a blower 448 (e.g. an air knife) and a vacuum cleaner 449. Different combinations of cleaning devices are possible.

[0080] After removal of the mask pattern and/or unsolidified residues, one or more further topcoat layers 430b may be applied in the same way as the first topcoat layer 430a.

[0081] FIG. 5 illustrates yet a further embodiment of the proposed method for producing a decorative surface covering.

[0082] First, a structural core 510 (including one or more support layers 512 and a dcor-receiving layer 514) receives a digitally printed two-dimensional dcor 525, before a spacer layer 528 is laminated with the structural core 510. The layer assembly thus formed is cut into slabs 550.

[0083] The slabs 550 are input into a digital embossing equipment, wherein a coating layer 552 is applied on the side of the spacer layer 528 that faces away from the dcor layer. An embossing tool is created by digital 3D printing of a negative 555 of the desired three-dimensional surface relief 530. In the illustrated embodiment, the negative 555 is 3D printed on the surface of a cylinder 554, which is pressed against the slabs 550 so as to emboss the digitally printed surface structure into the coating layer 552. The angular speed of the cylinder 554 is controlled such that the contact between the cylinder 554 and the slabs 550 takes place essentially without slippage. It is worthwhile noting that the embossing tool could alternatively by created by digital 3D printing of a negative 555 of the desired three-dimensional surface relief 530 on a plate or a die.

[0084] The relief 530 is thereafter fixed in the coating layer by solidification of the latter (this may include fusion, drying and/or curing, depending on the type of coating composition). In the example of FIG. 5, solidification is carried out using a radiation-curing device 535.

[0085] The negative(s) 555 on the cylinder 554 could serve plural times if they are not damaged by the embossing. It will be appreciated, however, that for each slap, a different negative could be generated on-the-fly. This makes it possible to create surface coverings with unique designs (dcor and corresponding embossing). Negatives may be removed from the cylinder using a scraper or knife 556. The material of the negatives could be recycled.

[0086] While specific embodiments have been described herein in detail, those skilled in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.