Method and Device for Providing Laminate Panels Provided with Individualized Decorations

Abstract

Provided is a method for making laminate panels having individualized decors, in particular wood-based laminate panels, for a party B, in particular an end user, including the steps of providing at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, wherein the laminate panel blank includes a carrier plate pressed with a coating as a print base coat and at least one backing and connecting elements inserted into the panel edges, printing of at least one decor individually selected by the party B, in particular the end user, on the laminate panel blank by digital printing; and pressing at least one thermoplastic film onto the printed decoration as a wear layer.

Claims

1. A method for providing laminate panels provided with individualized decors, in particular wood-based laminate panels, for a party B, in particular an end user, comprising the steps of: providing at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, wherein the laminate panel blank comprises a carrier plate pressed with a coating as a print base coat and at least one backing and connecting elements inserted into the panel edges, printing of at least one decor individually selected by the party B, in particular the end user, on the laminate panel blank by digital printing; and pressing at least one thermoplastic film onto the printed decoration as a wear layer, wherein the printing of the selected decoration and the pressing of the at least one thermoplastic film onto the printed decoration is performed at the point-of-sale (POS).

2. The method according to claim 1, wherein the at least one print base coat of the laminate panel blank comprises a resin provided with color pigments, preferably a pigmented formaldehyde resin.

3. The method of claim 1, wherein the at least one print base coat of the laminate panel blank is a colored paper impregnated with a resin.

4. The method according to claim 1, wherein the at least one print base coat of the laminate panel blank is provided with a texture.

5. The Method according to claim 1, wherein at least one primer layer is provided on the at least one print base coat of the laminate panel blank.

6. The method according to claim 1, wherein the at least one decorative print is provided in the form of individualized computer data/software.

7. The method according to claim 1, wherein the at least one thermoplastic film provided as a wear layer is a transparent cover film made of a thermoplastic material, in particular thermoplastic polyurethane (TPU), polyethylene terephthalate (PET) or polypropylene (PP).

8. The method according to claim 1, wherein at least one thermoplastic film is applied to the printed panel blank at a temperature that is up to 20° C. above the softening temperature of the thermoplastic material of the film.

9. The method according to claim 1, wherein at least one lacquer layer is provided on the at least one thermoplastic film.

10. The method according to claim 1, wherein the at least one thermoplastic film and the lacquer layer optionally provided thereon are provided with a structuring.

11. A laminate panel, in particular wood-based laminate panel, which can be produced in a method according to claim 1, comprising a layered structure comprising at least one backing, a carrier board, at least one print base coat, optionally at least one primer layer, at least one (individualized) printed decorative layer, at least one thermoplastic film and optionally at least one lacquer layer.

12. A device for providing a laminate panel provided with individualized decorations at a point-of-sale (POS) in a method according to claim 1, comprising at least one digital printer for printing at least one decor on a laminate panel blank comprising a carrier plate pressed with a coating as a print base coat and at least one backing and connecting elements inserted into the panel edges, by digital printing; and at least one roller device for pressing at least one thermoplastic film as a wear layer onto the print decoration.

13. The device according to claim 12, wherein the at least one digital printer is connected to at least one electronic data processing device.

14. The device according to claim 12, wherein the at least one roller device comprises at least one roller with a structured roller.

15. The device according to claim 12, wherein the at least one digital printer and the at least one roller device are adapted to the dimensions of the laminate panel blank.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0071] The solution is explained in more detail below with reference to a figure and an example of an embodiment.

[0072] FIG. 1 shows a schematic representation of an embodiment of the present method.

DESCRIPTION OF THE INVENTION

[0073] FIG. 1 shows a schematic representation of a process for finishing a laminate panel blank, such as may be carried out in a processing plant, for example a franchisee associated with the laminate manufacturer, a hardware store or similar.

[0074] The laminate panel blanks 101 are delivered from the laminate manufacturer to the processing plant in transport-safe packaging. In a first process step, the laminate panel blanks 101 are removed from this transport-safe packaging and fed into a magazine.

[0075] In the example of the process shown in FIG. 1, the laminate panel blanks 101 are then fed to a cleaning device 102, in which the surface of the laminate panel blanks 101 is cleaned of any dirt and dust that may have adhered and is thus prepared for printing. However, it is also conceivable that the laminate panel blanks 101 have been suitably cleaned in the laminate manufacturer's plant for subsequent printing. They may then have been cleaned and placed in the transport-safe packaging. For example, by sealing the transport packaging airtight in a film, it can be ruled out that the laminate panel blanks 101 subsequently have to be cleaned again before they are printed.

[0076] After the laminate panel blanks 101 have passed through the cleaning device 102, if necessary, they are aligned and spaced apart from each other to the desired distance. The laminate panel blanks 101 are then fed to a digital printer 103. Here, the surface of the panel 101 is printed with the decorative layer to be applied. The digital printer 103 has three print heads for this purpose. Depending on the desired decor, the digital printer 103 can also have more or fewer print heads. Connected to the digital printer 103 is an electronic data processing device 104, which has an input device not shown in FIG. 1, via which the user of a device for carrying out the process can select the desired decor. For this purpose, the electronic data processing device 104 has a display device via which the available decors, which are stored on an electronic storage medium, for example, are displayed to the user. From this selection, the user can select the desired print decor.

[0077] To ensure the best possible result, the decors are optimized and adapted in the data processing device 104 to the possible formats of the laminate panel blanks 101 to be printed.

[0078] After the top side of the laminate panel blanks 101 has been printed with a decor, the printed panels 101 leave the digital printer 103 and are fed to a roller device 105 in which a transparent thermoplastic wear film is pressed on. The film is cut to size after the pressing process. If necessary, cooling (roller cooling) can also be integrated into the process. After pressing the wear-resistant foil with the printed panel, the end user is provided with a laminate panel adapted to his individual wishes, which can be used, for example, as a flooring element or also for wall or furniture cladding.

Example

[0079] Provision of the Laminate Danel Blanks at the Laminate Manufacturer:

[0080] The large-format wood-based panels are base coated. The base coat can either have a solid-coloured paper as a base or consist of a liquid coating with subsequent covering with a melamine resin coating. The liquid coating can be applied by roller application or also by digital printing.

[0081] In the case of an impregnate, a dyed paper is subjected to a special impregnation. First, the paper is filled with resin, then sharply squeegeed on the upper side with a knife squeegee and then given a resin coating on the underside to improve adhesion to the substrate.

[0082] Base coating is usually done on a large format (format 2800 mm×2070 mm with a thickness of 4 to 15 mm, preferably 6 to 12 mm).

[0083] In each case, subsequent pressing has been carried out in a short-cycle press with a counter-draught.

[0084] The laminate flooring blanks are then produced from this large format on a milling line.

[0085] A primer can be applied before or after formatting to improve the adhesion of the film applied later.

[0086] This primer is applied in a quantity of 10 to 20 g fi/m.sup.2. It can be an isocyanate-based or silane-based primer (INOFLEX NI+). A separating film can be provided to protect the primer from soiling and from bonding of the laminate flooring blanks during transport and storage.

[0087] Locking profiles (fasteners and locking elements) are worked into the side edges of the formatted panel blanks, usually by milling and, if necessary, with plastic locking elements, then packaged, temporarily stored if necessary and shipped to the point of sale.

[0088] At the laminate manufacturer, a “ready-made” laminate in the colour white is produced and stored in stock, so to speak.

[0089] Refinement at the Point of Sale (e.g. Hardware Store):

[0090] The laminate panel blanks are unpacked and cleaned and fed into the system consisting of digital printer and roller device.

[0091] The system includes a magazine in which laminate panel blanks (coated, primed and tongue and groove) are located.

[0092] At the point of sale, the laminate flooring blanks are printed with a digital printer either with decors provided by the system supplier or with decors that the end user transfers to the system via a file. It is also possible to integrate inlays, names, etc. in a decor provided by the system supplier. Further processing of the decor files is also possible via simple software (rotating, mirroring, enlarging, reducing, etc.). In addition, the result of the adjustments can be examined not only on a screen but also on a printout.

[0093] A TPU film with a UV lacquer coating on the top is then laminated onto the print using a heated roller at a pressure of 150 N/mm and a temperature of 140° C. The film is fed from a roll. After the lamination process, it is cut to size. The blanks are transported through the laminating press by a guide, which is equipped to prevent damage to the profile areas during lamination.

[0094] The heated roller, which presses the film onto the print, is structured so that the lacquer coating surface can be restructured. The rollers can also be changed automatically via a changeover system so that structures can also be varied. The temperature used to apply the film is up to approx. 20° C. above the softening temperature of the thermoplastic from which the film was made. The fact that the laminate flooring blanks are delivered to the POS solves the problem of supplying end customers with small quantities, which has arisen due to customization. Furthermore, all that is needed for surface finishing is a digital printer and roll lamination in the plank width. If required, foils for different usage classes can also be used, as this only requires the exchange of one roll.