Method for producing decorative prints having identical quality independently of the printing method used and a device for performing said method

Abstract

The present invention relates to a method for producing decorative prints having identical quality on at least two carrier materials comprising the following steps: a) providing at least one print motif; b) converting the at least one print motif into at least one high resolution electronic data set having a resolution of up to 1200 dpi, preferably 1000 dpi, by means of at least one image processing software; c) reducing the resolution of the at least one high resolution electronic data set down to 100 dpi, preferably 60 to 80 dpi, by means of at least one image processing software; d) creating at least one first print dcor on at least one first carrier material by using at least one digital printer by means of the at least one resolution reduced electronic data set; e) creating at least one print cylinder for a gravure printing process by using at least one resolution reduced electronic data set, wherein the resolution reduced electronic data set can be identical to or different from the resolution reduced electronic data set used for the digital printing; and f) creating at least one second print dcor on at least one second carrier material by using the at least one print cylinder. The invention further relates to a device for performing said method.

Claims

1. A method for producing decorative prints having identical quality on at least two carrier materials comprising the following steps: a) providing at least one print motif; b) converting the at least one print motif into at least one high resolution electronic data set having a resolution of up to 1200 dpi by means of at least one image processing software, b1) adapting the high-resolution data set of the printing motif to changes relating to decoration and/or color, c) reducing the resolution of the at least one high resolution electronic data set down to 100 dpi by at least one image processing software, d) printing via a digital printer at least one first print dcor from the reduced electronic data set on at least one first carrier material, e) engraving at least one print cylinder for a gravure printing process using the reduced resolution electronic data set, and f) printing at least one second print dcor on at least one second carrier material through the gravure printing process by using the at least one print cylinder.

2. The method according to claim 1, wherein the at least one print motif is processed by the at least one image processing software for adjusting the motif beginning and motif end by forming a continuous motif.

3. The method according to claim 1, wherein step b1) markings are introduced into the decoration as processing means for the carrier material to be printed.

4. The method according to claim 3, wherein the markings introduced into the decoration represent cutting or identification marks.

5. The method according to claim 4, wherein the cutting or identification markings introduced into the decoration consist of non-visible ink, in particular, IR ink.

6. The method according to claim 3, wherein the markings introduced are configured to be read by using appropriate detection devices.

7. The method according to claim 1, wherein step b1) further comprises introducing individualized elements into the data set.

8. The method according to claim 7, wherein the elements of individualization are knotholes or cracks, stone dcors with fossilizations, or inclusions or phantasy dcors with figures or toys.

9. The method according to claim 1, wherein the at least one first carrier material and the at least one second carrier material are the same.

10. The method according to claim 1, wherein that the first and the second carrier material are selected from a group consisting of paper, glass, metal, films, wood products, MDF or HDF boards, veneers, varnish layers, plastic boards, and inorganic carrier boards.

11. The method according to claim 1, wherein the number of pixels per unit area applied by means of digital printing to the first carrier material is equal to the number of pixels per unit area applied by means of gravure printing to the second carrier material.

12. The method according to claim 1, wherein the at least one first print dcor, created by means of digital printing, and the at least one second print dcor, created by means of gravure printing using the print cylinder, are printed onto evenly pre-primed carrier materials.

13. The method according to claim 1, wherein an electronic standard data set is generated for gravure printing by using the print cylinder and an electronically individualized data set is generated for digital printing.

14. The method according to claim 1, wherein used print liquids contain identical pigments.

15. The method according to claim 1, wherein a protective layer is applied to the print dcor or the print dcors.

16. The method according to claim 1, wherein the printed carrier material is further processed in a short cycle (KT) press.

17. A device for producing dcor prints having identical quality on at least two carrier materials from a starting data set comprising: at least one means for converting at least one print motif into at least one high resolution electronic data set with a resolution of up to 1200 dpi; at least one means for reducing the resolution of the at least one high resolution electronic data set down to 100 dpi, to create at least one resolution reduced electronic data set; at least one first printing line with a digital printer for creating at least one first print dcor on at least one first carrier material by using the at least one resolution reduced electronic data set; and at least one second printing line with a print cylinder for a gravure printing process for creating at least one second print dcor on at least one second carrier material, wherein the at least one print cylinder was created by using the at least one resolution reduced electronic data set.

18. The device according to claim 17, wherein the first and the second printing line use print liquids with the same pigment basis.

19. The device according to claim 17, further comprising at least one means for applying a protective layer to the carrier material provided with the respective print dcor.

20. The device according to claim 17, further comprising at least one short cycle press for pressing the carrier material provided with the dcor and the protective layer arranged thereon.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic view of a method for producing decorative prints according to an embodiment of the present invention;

(2) FIG. 2 is an alternative schematic view of a method for producing decorative prints according to an embodiment of the present invention; and

(3) FIG. 3 is a schematic view of an embodiment of optional additional steps of the method of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

(4) Additional details and advantages of the present invention will become apparent upon review of the following Detailed Description with reference to the accompanying Figures.

(5) The present method according to the invention comprises the steps: a) providing at least one print motif; b) converting the at least one print motif into at least one high resolution electronic data set having a resolution of up to 1200 dpi, preferably 1000 dpi, by means of at least one image processing software; c) reducing the resolution of the at least one high resolution electronic data set down to 100 dpi, preferably 60 to 80 dpi, by means of at least one image processing software; d) creating at least one first print dcor on at least one first carrier material by using at least one digital printer by means of the at least one resolution reduced electronic data set; e) creating of at least one print cylinder for a gravure print process by using at least one resolution reduced electronic data set, and f) creating at least one second print dcor on at least one second carrier material by using the at least one print cylinder. See the accompanying Figure showing a schematic representation of an embodiment of the method according to the present invention.

(6) The software used in the steps b) and c) is thereby preferably identical. Accordingly the present method uses a resolution reduced electronic data set for controlling a digital printer as well as for creating a print cylinder/a print cylinder set and the use thereof in a gravure printing process for dcor coating a further carrier material. Thus, an adaptation of the resolution and optionally of the color of the prints starting from the same digital data set takes place.

(7) The first print dcor applied by digital printing and the second print dcor applied by gravure printing are preferably identical so that a direct comparison of the print quality is provided. Thus it is possible to present a test sample with a specific dcor produced by digital printing to a customer and to transfer said print dcor after approval by the customer to the mass production by means of the cheaper gravure printing without quality loss.

(8) Referring now to FIG. 2, an embodiment of process according to the present invention is illustrated. First a print motif 10 is scanned into a scanner 20 to convert the print motif 10 into a high resolution electronic data set 13. The high resolution electronic data set 13 may then be transferred to an image processing software 35 located on a computer 30, which is used to reduce the resolution of the high resolution electronic data set 13 to create a reduced resolution electronic data set 15. The reduced resolution electronic data set 15 is then sent to a digital printer 40 to print a first print dcor from the reduced resolution electronic data set 15 on a first carrier material 50. The reduced resolution electronic data set 15 can also be used to create a gravure cylinder 45. The gravure cylinder 45 can then be used to print a second print dcor on a second carrier material 55 through a gravure printing process using the gravure cylinder 45, which was created with the reduced resolution electronic data set 15.

(9) As illustrated in FIG. 3, the first and second carrier materials 50, 55 with printed dcors from the digital printer 40 and gravure cylinder 45, respectively, may then be further processed by receiving a protective layer from a means for applying a protective layer 60, 65. Even further processing may occur, wherein the first and second carrier materials 50, 55 now having a protective layer, can be pressed by short cycle presses 70, 75. Although the processes shown herein in FIG. 3 are depicted as having separate means for applying a protective layer 60, 65 and separate short cycle presses 70, 75 for the first and second carrier materials 50, 55, respectively, it is contemplated that the process may also include a single means for applying a protective layer and/or a single short cycle press for processing the first and second carrier materials 50, 55 from both the digital printer 40 and gravure cylinder 45 lines, respectively.

(10) As mentioned above at first a print motif is provided, wherein typically different dcors as for instance veneers with wood grains, tile patterns, parquet imitations or fantasy patterns can be used as print motifs.

(11) In a variant of the present method the at least one print motif is processed by the at least one image processing software not only into an electronic data set but is also simultaneously processed for adjusting the motif beginning and motif ending by forming a continuous motif.

(12) It is also possible to adapt the high resolution data set of the print motif or print dcor and/or to color changes. Thereby for instance markers can be applied as processing aids as for instance cutting or identification marks of non-visible ink, as IR ink, which can be read by means of appropriate detection devices. Of course also further changes or adaptations of the print motif can take place by changing or amending the data set.

(13) The high resolution electronic data set created in step b) can be used for digital printing and comprises data for controlling the digital print. An application of such a high resolution data set in an analog method as for instance the gravure printing process however would not be possible.

(14) Accordingly it is necessary to reduce the resolution of the at least one high resolution electronic data set according to step c) by using at least one image processing software such that the data set can be used for engraving print cylinders.

(15) The at least one first carrier material and the at least one second carrier material used in the present method can be the same or different and can be selected from a group consisting of paper, glass, metal, films, wood products, in particular MDF or HDF boards, veneers, varnish layers, plastic boards and inorganic carrier boards.

(16) In a preferred embodiment of the present method, the number of pixels per unit area applied by means of digital printing to the first carrier material is equal to the number of pixels per unit area applied by means of gravure printing to the second carrier material. Accordingly, it is preferred, if the number of pixels per unit area applied to the carrier material is independent on the applied printing method, i.e., it makes no difference if digital printing or gravure printing are used.

(17) In a further variant of the present method the printing dcor created by means of digital printing and the printing dcor created by means of gravure printing using the print cylinder are printed on an evenly pre-primed carrier materials.

(18) The carrier materials can be pre-treated for instance with a primer layer of a resin and/or a lacquer. Thereby, an aqueous resin solution and/or a radiation curable filling compound can be applied for priming to the side of the carrier material to be printed. For instance, aqueous formaldehyde containing resin solutions such as melamine formaldehyde resin, urea formaldehyde resin or melamine urea formaldehyde resin can be used as priming means. It is also possible to pre-coat or to prime the carrier material with UV-filler and/or ESH-filler and to cure subsequently said priming layer.

(19) As described, in a further preferred variant of the present method at first a data set with reduced resolution is used for the digital printing as well as also for creating the cylinder set as so called standard data set. Subsequently, the dcor data set can be provided electronically with individualizations, as for instance for wood dcors with knotholes or cracks, for stone dcors with fossilizations or inclusions or for phantasy dcors with figures or toys.

(20) Said individualized dcor data set can be used either in a high resolution or in a reduced resolution for the digital printing. The question, with which resolution the individualized data set is used, depends essentially on the fact how the collections are positioned or if eventually a higher sales revenue can be obtained by individualization. Thus, the customer could be offered in case of a higher sales revenue the additional benefit of a higher resolution. If the product on the other side is to be offered as cost-efficient as possible, a reduced resolution of the data set is preferably chosen. The performance of the printer decreases significantly with higher resolution.

(21) In the production line it is then possible to create mixed print dcors. Thus, a pre-determined number of boards, for instance five boards, can be printed using the standard data set in gravure printing and a subsequent number of further boards, for instance two boards, can be printed using the individualized data set by digital printing. Thereby, it is possible to react to customer wishes and also better prices can be obtained with the individualized dcors.

(22) In a further variant of the present method, the print liquids used for digital printing and for gravure printing contain identical pigments, whereby solvent and binder of the print liquids to be used can be different. The print colors for the gravure printing and the inks for the digital printing method have accordingly the same pigment basis, which provide comparable or identical results during printing.

(23) It is also possible to apply at least one protective layer to the dcor or dcors, in particular a protective layer comprising abrasion-resistant particles, natural fibers, synthetic fibers and/or further additives, wherein resins such as melamine formaldehyde resin, or urea formaldehyde resin, acrylate resins and polyurethane resins can be used as suitable binders.

(24) The abrasion-resistant particles are preferably selected from the group containing aluminumoxide, korund, borcarbide, siliciumdioxide, siliciumcarbide and glass beads. As natural and/or synthetic fibers, in particular fibers selected from the group containing wood fibers, cellulose fibers, wool fibers, hemp fibers and organic or inorganic polymer fibers are used.

(25) As additives conductive substances, flame retardants, luminescent compounds and metals can be added. Thereby, the conductive substances can be selected from the group containing carbon black, carbon fibers, metal powder and nanoparticles, in particular carbon nanotubes. Also, a combination of these substances can be used. As flame retardants preferably phosphates, borates, in particular ammoniumpolyphosphate, tris(tribromneopentyl) phosphate, zincborate or boric acid complexes of multivalent alcohols can be used. As luminescent compounds preferably fluorescent and/or phosphorescent compounds on an inorganic or organic basis, in particular zinc sulfide and of earth alkali aluminates can be used.

(26) In a further embodiment of the present method the printed carrier material, which is optionally provided with a protective layer, is further processed or refined in a short cycle (KT) press. In the KT-press the resin layers are melted and the layer composite is hardened to a laminate. During the further processing in the KT-press surface structures can also be created in the surface of the carrier material, such as a wood based board, using a structured press plate, wherein the surface structures can be optionally implemented matching the dcor (so-called dcor synchronic structure). In case of wood dcors, the structures can be present in form of pore structures, which follow the grain. In case of tile dcors the structures can be depressions in the area of grove lines comprised by the dcor.

(27) The present method offers multiple advantages. The sorted and selected carrier materials provided with printing dcors can be immediately presented to the customer. It is possible to create any color positions as well as to introduce a digital finishing work. The dcors or products with the corresponding dcors can also be produced in any amount and a fast delivery is possible without creating print cylinders. The use of the master data set for premium products using the data set with highest resolution is also possible and remaining stocks of different value added levels are avoided.

(28) The presently described method has the advantage that a fast supply of products with adapted colors is possible and only later depending on the market success of the product the best production method can be selected. The disadvantage of higher cost is limited to the poorly selling dcors or initial productions. Furthermore, the development of dcors within the product life circle can be better considered. Thus, a small amount is digitally printed for sorting or presentation of photo type samples and the large amounts resulting therefrom are subsequently produced by gravure printing. At the end of the life cycle of a product small amounts can again be produced digital. The further advantage is that in a production line, which comprises the possibilities of gravure printing as well as digital printing a dcor can be processed in a manner that individualized and non-individualized are mixed.

(29) The present method is carried out in a device for producing dcor prints with identical quality on at least two carrier materials from a starting data set, wherein the device comprises the following elements:

(30) at least one means, for instance an image processing software, for converting at least one print motif into at least one high resolution electronic data set with a resolution of up to 1200 dpi, preferably 1000 dpi;

(31) at least one means, for instance an image processing software, for reducing the resolution of the at least one high resolution electronic data set down to 100 dpi, preferably 60 to 80 dpi;

(32) at least one first printing line with a digital printer for creating at least one first print dcor on at least one first carrier material and the use of the at least one resolution reduced electronic data set, and

(33) at least one second printing line with a print cylinder for a gravure printing process for creating at least one second print dcor on at least one second carrier material, wherein the at least one print cylinder was created by using at least one resolution reduced electronic data set, and wherein the resolution reduced electronic data set can be the same or different from the resolution reduced electronic data set reduced for the digital printing in the first printing line.

(34) As previously described for the method the used carrier material can be the same or different.

(35) Print liquids with the same pigment basis can also be used in the first and second printing line for the gravure printing and the digital printing, i.e. the used print liquids can comprise identical pigments.

(36) In a further variant the present device comprises at least one means for applying a protective layer to the carrier material provided with the respective print dcor. Said means or device for applying a protective layer is arranged preferably subsequently to the first printing line or the second printing line.

(37) In a preferred embodiment the present device comprises at least one short cycle press for pressing the carrier material provided with a print dcor and the protective layer arranged thereon. Hereby at least one short cycle press can be assigned to each printing line or it is also conceivable that the carrier materials leaving the first and the second printing line and provided with the respective print dcor can be fed to a single short cycle press.

(38) The invention is subsequently described with reference to an example.

EXAMPLE

(39) A veneer (14002070 mm) is scanned in a scanner with a resolution of 1000 dpi.

(40) By adjusting using an image processing software the transition at the beginning and the end of the dcor can be aligned so that an endless dcor is obtained.

(41) The processing of wood grains can be also carried out or elements for individualization such as knotholes, cracks and so on can be integrated.

(42) Furthermore, cutting, identification markers or other processing means can be applied. They can be realized also with non-visible inks (IR ink) in case of the digital printing, which are recognized later by appropriate detection devices.

(43) The electronic data set is subsequently reduced by the image processing software to a resolution, which is suitable for the engraving of print cylinders (60-80 dpi).

(44) First samples are than created on a digital printer using this data set, which can still be adapted in color after consultation. Papers, films, wood boards, veneers, lacquer layers, plastic boards, inorganic carrier boards and so on can thereby be used for the prints as carrier materials.

(45) In parallel cylinders are created for the production of the dcor in gravure printing process using the data set.

(46) Subsequently the dcors, which can be realized by gravure printing and digital printing, are printed onto evenly pre-primed carriers. A mixed print can thereby be carried out when using carrier boards. The standard data set is created in gravure printing and the individualized data set is produced by the digital printer. Thus it is possible to produce a floor for customer, which consists of a mixture of standard and individual panels based on a floor.

(47) The method is not limited to the production of wood reproductions. Any template can be digitalized, processed and printed or pressed to the different carrier materials.