METHODS FOR MANUFACTURING DECORATIVE PANELS AND PANELS OBTAINABLE THEREBY

Abstract

A method for manufacturing decorative panels, where the panel includes a panel substrate material and a top decorative layer. The method includes applying the top decorative layer to the panel substrate material at least through additive manufacturing techniques, more particularly through material jetting. The Process further concerns panels obtained or obtainable through such method.

Claims

1. A method for manufacturing decorative panels, wherein the method comprises at least the following steps: the step of providing a panel substrate material; the step of depositing relief forming material on the substrate material with a first deposition device; the step of depositing decor forming material on the substrate material with a second deposition device; wherein at least the step of depositing relief forming material and the step of depositing decor forming material are performed in a single movement of the panel substrate material relative to said first and second deposition device.

2. A method for manufacturing decorative panels, wherein the method comprises at least the following steps: the step of providing a panel substrate material; the step of depositing relief forming material on the panel substrate material with a first deposition device; the step of depositing decor forming material on the panel substrate material with a second deposition device; wherein both said first and second deposition device comprise nozzles projecting the respective material to the panel substrate material, and in that the nozzles of said first deposition device are at a larger distance to the surface of the panel substrate material, than the nozzles of said second deposition device.

3. A method for manufacturing decorative panels, wherein the method comprises at least the following steps: the step of providing a panel substrate material; the step of depositing relief forming material on the panel substrate material with a first deposition device; the step of depositing decor forming material on the panel substrate material with a second deposition device; wherein said first deposition device deposits relief forming material having a particle size larger than 20 micrometer and/or with a drop volume larger than 100 picoliter, and said second deposition device deposits decor forming material with a drop volume smaller than 50 picoliter.

4. A method for manufacturing decorative panels, wherein the method comprises at least the following steps: the step of providing a panel substrate material; the step of depositing relief forming material on the panel substrate material with a first deposition device; the step of depositing decor forming material on the panel substrate material with a second deposition device; wherein said first deposition device deposits relief forming material at a resolution of below 100 dpi, while said second deposition device deposits decor forming material at a resolution above 200 dpi.

5. The method for manufacturing decorative panels according to claim 4, wherein the method further comprises the step of depositing hard particles on the background forming material and/or the step of incorporating hard particles in the background forming material.

6. The method for manufacturing decorative panels according to claim 4, wherein the method comprises the step of depositing a clear coating material on the substrate material; wherein said clear coating material is digitally applied with a resolution above 300 dpi, preferably above 900 dpi.

7. The method in accordance with claim 6, characterized in that the method further comprises the step of curing said clear coating material, wherein said curing is controlled digitally.

8. The method according to claim 7, characterized in that said digitally controlled curing comprises applying different pinning and cure settings to said clear coating material.

9. The method according to claim 4, characterized in that said panel substrate material is provided in the final shape, or about in the final shape.

10. The method according to claim 4, characterized in that said panel substrate material comprises a uniformly colored top surface.

11. The method according to claim 4, characterized in that said panel substrate material comprises a flat top surface or a structured top surface.

12. The method according to claim 4, characterized in that a relief forming material is applied which comprises a polymer filled with at least 30 wt % of filler materials.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0160] With the aim of better describing the prior art as well as the invention, here below as examples without limitative character, some preferred embodiments are described with reference to the attached figures, wherein:

[0161] FIG. 1 schematically represents some steps m a method according to the invention for a potential product build-up;

[0162] FIGS. 2A, 2B, 2C and 2D show some photographs of a decorative panel obtained with the method of FIG. 1;

[0163] FIG. 3 schematically represents a decorative panel with a top decorative layer obtained through a method of the invention;

[0164] FIG. 4 schematically illustrates a second concept of the invention;

[0165] FIG. 5 schematically represents some steps in a method according to the invention for a potential product build-up;

[0166] FIG. 6 schematically represents a view in perspective of the decorative panel after step Al of the method of FIG. 5;

[0167] FIG. 7 schematically represents a view in perspective of the decorative panel after step A4 of the method of FIG. 5;

[0168] FIG. 8 schematically represents a decorative panel with a top decorative layer obtained through a method of the invention;

[0169] FIGS. 9, 10 and 11 schematically represents some steps in a method according to the invention for a potential product build-up.

DETAILED DESCRIPTION OF THE INVENTION

[0170] The reference numbers used in the figures are partly defined in the claims.

[0171] Figure I schematically represents possible steps in a method for manufacturing a decorative panel 8 in accordance with the invention. The exemplified method starts with providing the panel substrate material 1, preferably a HOF substrate material. The panel substrate material I may optionally be structured in a step SI by milling, possibly enc milling (computer numerically controlled), and/or laser machining. The method comprises the step S2 of depositing relief forming material 2, the step S4 of depositing background forming material 5, the step of depositing hard particles 6A, the step S3 of depositing decor forming material 3, the step of depositing hard particles 6B and the step of depositing clear coating material 7.

[0172] As aforementioned the method of FIG. 1 comprises the step S2 during which a relief forming material 2 is deposited. The relief forming material 2 comprises white, beige, brown and grey (W, B1, B2, G) relief forming material which are deposited subsequently and cured in a curing step C1. In step S2 a colored base structure, preferably a macrostructure, is created. The relief forming material may be a colored photopolymer including fillers, which may be jetted and/or deposited by scattering colored powder and jetting binder.

[0173] Next, in the example of FIG. 1, step S4 is performed during which a background forming material 5 is deposited as a first print layer or background forming layer SA. In this case the background forming material is printed using CMYK (Cyan, Magenta, Yellow, Key-black) colors CMKB 1, optionally followed by a curing in a curing step C2. Such curing step may a thermal cure or a UV cure. Alternatively instead of CMYK colors, spot colors may be used. As is known in the art, spot colors are premixed colors which preferably appear in the design to be obtained.

[0174] On top of this background forming layer SA a first anti-abrasion layer 6A is formed in the step SS. This is realized by applying mineral particles, for example by scattering Alox (Aluminiumoxide particles), by binder and powder jetting, or by using a piezo needle.

[0175] In a further process step S3, a decor forming material 3 is deposited to form a second print layer 3A. Also in this case CMYK colors CMYK 2 or spot colors may be used. The print may be performed in high resolution and is optionally followed by a curing in a curing step C3. Such curing step may be a thermal cure or a UV cure.

[0176] In next step SSB, a second anti-abrasion layer 6B is formed by applying mineral particles, for example by scattering Alox (aluminiumoxide), by binder and powder jetting, or by using a piezo needle.

[0177] In a further step S6, as shown in FIG. 1, a microstructure and variable gloss are formed. This is realized by depositing clear coat material 7, optionally including a matting agent, in a step CCI, to form a clear coating layer 7 A The clear coating layer 7 A may be performed in very high resolution, preferably 1200 dpi, and is followed by a curing step C4. Such curing step may be a thermal cure or a UV cure. Subsequently, a clear coat material, optionally including a matting agent, is deposited in a step CC2. The clear coating layer may be performed in very high resolution, preferably 1200 dpi, and is cured in a curing step CS. Such curing step may be a thermal cure, a UV cure or an excimer cure. Curing C4 and curing CS are steps S6B. Matt/gloss may be obtained with various pinning and cure settings.

[0178] Where in the above binder and powder jetting is mentioned preferably a technique is meant in which a binder is printed in a pattern, a powder is deposited uniformly, the binder is cured, and the unbound powder is removed.

[0179] FIGS. 2A, 2B, 2C and 2D shows several views on the obtained decorative panel 8. FIG. 2A shows a substrate 1 with its substrate's surface 4. FIG. 2B shows a decorative panel 8 obtained with the method of FIG. 1. FIG. 2C shows a cross-section according to F2C, and shows the substrate 1, the substrate's surface 4, a relief forming material 2, a decor forming material 3, the second print layer 3A, clear coating material 7, and the clear coating layer 7 A. Top layer 9 comprises the relief forming material 2, the dcor forming material 3, the second print layer 3A, the clear coating material 7, and the clear coating layer 7A. FIG. 2D shows another cross-section, and shows the substrate 1, a relief forming material 2, and a decor forming material 3, the second print layer 3A, a clear coating material 7, the clear coating layer 7 A, and a relief 11. Top layer 9 comprises the relief forming material 2, the decor forming material 3, the second print layer 3A, the clear coating material 7, and the clear coating layer 7A.

[0180] FIG. 3 shows a conceptual build-up of the top decorative layer 9. From bottom to top on the panel substrate material 1 may be applied:

[0181] An adhesion primer (AP). This may be applied by means of one or more rollers, or by means of a valvejet or other digital deposition device. Preferably a uniform coating is applied, preferably a coating extending over the entire surface 4, or substantially the entire surface 4 of the panel substrate material 1;

[0182] A digitally deposited structure, preferably macrostructure (MS), such as a relief forming material layer 2. The digitally deposited structure may be applied with a low resolution at high volume application rates. The applied material may be highly filled, for example with a filling rate of 40 weight percent or more. For the application low resolution piezo inkjetheads, pistons or a valvejet may be used. The thickness of this layer may be between 50 and 300 micrometer;

[0183] A preprint fond layer (PF), such as a background forming material 5 and a background forming material layer SA. The preprint front layer seeks to add a uniform coloring or a low resolution print. The preprint front layer may be applied by means of low resolution piezo inkjetheads;

[0184] A first anti-abrasion layer (AA1) with hard particles 6A. The hard particles 6A may be applied with scattering, piezo needle or similar;

[0185] An inkjet primer 13 (UP). An inkjet primer 13 may be applied with one or more rollers, with valvejet, by spraying or by curtain coating. Preferably a uniform coating is obtained;

[0186] A second print layer 3A, such as a CMYK high detailed inkjet print layer (CMYK 3). The second print layer 3A is preferably applied by using high resolution piezo inkjet heads and is preferably obtained from decor forming material 3;

[0187] A second anti-abrasion layer (AA2) with hard particles 6B, preferably including structure in itself. The second anti-abrasion layer may be applied by means of one or more rollers or by means ofvalvejet. Preferably a substantially uniform coating is obtained;

[0188] A clear coating layer 7 A, such as a high detailed clear coating layer (MSG) which may have a mat and/or gloss microtexture. The clear coating layer 7 A is preferably applied by means of a high resolution piezo inkjet head and is preferably obtained from clear coating material 7. The clear coating layer 7 A may be applied in several steps with intermediate curing. Lacquers with various gloss levels may be applied one after the other. The intermediate curing steps may be executed using excimer curing and/or UV curing. Preferably for obtaining varying gloss levels, UV LED pinning is applied with various intensities and timing of pinning.

[0189] FIG. 4 shows that the method of the invention allows for creating a decorative panel 8 with a structure 11 having undercuts 12. This is obtained by depositing a removable, e.g. washable, solvable or meltable, support material 13 on the surface of the substrate 4, at the location where the undercut 12 is to be formed. The material 14 overhanging the undercut 12 is then first deposited and possibly cured. Afterward the support material 13 is removed actively by washing, solving or melting, or vanishes by itself for example because it degrades. Possible support materials 13 may be polyethyleneglycol-based (PEG), polyvinylalcohol-based (PV A) or wax-based. These materials may be jetted at 50 to 80 C., solidify on the panel substrate material 1 at room temperature (25 C. or below). The support material 13 may in such case be removed at 40 or 50 C. using a solvent such as water.

[0190] FIG. 5 schematically represents possible steps in a method for manufacturing a decorative panel 8 according to the tenth aspect of the present invention. In a preliminary step A0, a panel substrate 1 is provided.

[0191] In a step A1 a contour forming material 16 is deposited on the panel substrate 1 by means of additive manufacturing, for example by means of material jetting. The contour forming material 16 at least partially defines the contours of one or more relieved features to be formed.

[0192] In a next step A2, filling-up material 17 is provided at least within one or more of the contours. In this case the filling-up material 17 is deposited within all contours. The filling-up material 17 is preferably deposited by means of traditional coating techniques, such as powder coating. The filling-up material 17 may comprise wood, cellulose of chalk.

[0193] In a next step A3 an adhesive 18 is applied within one more of the contours, in this case with all of the relevant filling-up material already present within the same contour. The adhesive 18 may be deposited by means of one or more additive manufacturing techniques, for example by jetting, such as material jetting.

[0194] In a further step A4, the adhesive 18 and the filling-up material 17 are cured and unbound or loose filling-up material is removed. The curing may be a thermal curing, a reactive curing or an UV curing. Upon curing, the adhesive 18 allows for mutual bonding of the filling-up material 17 to form a solid layer 19, and/or said adhesive 18 may allow for a bond being formed between said filling-up material 17 and said contour forming material 16, and/or between said filling-up material 17 and said panel substrate material 1.

[0195] FIG. 6 shows a view in perspective of the decorative panel obtained by a method as described in FIG. 5, after step Al of FIG. 5. Contour forming material 16 is deposited on the substrate 1 to form one or more contours.

[0196] FIG. 7 shows a view in perspective of the decorative panel obtained by a method as described in FIG. 5, after step A4 of FIG. 5. Filling-up material 17 and an adhesive 18 have been cured and a solid layer 19 is formed within the contour, whereas outside of the contour any filling-up material that was deposited has been removed due to the absence of a curing.

[0197] FIG. 8 shows the schematic representation of a decorative panel 8 with a top decorative layer obtained through a method according to the eleventh aspect of the invention. A first material layer 20 is deposited on the panel substrate material 1, preferably by means of one or more additive manufacturing techniques. On top of the first material layer 20, a first print layer 21 is deposited, using inkjet printing technology and CMYK inks. Next, an anti-abrasion layer 22 is deposited on top of the first print layer 21. On top of the antiabrasion layer 22, a second print layer 23 is deposited, using inkjet printing technology and CMYK inks. In a further step, a second material layer 24 is deposited on top of the second print layer 23. The second material layer may be deposited by means of one or more additive manufacturing techniques, such as material jetting. The second material layer 24 may be a relief forming material whereby preferably the maximum depth of the relief features D2 in the second material layer is smaller than the maximum depth of the relief features D 1 in the first material layer, i.e. the first material layer 20 represents a macrostructure and the second material layer 24 represents a microstructure.

[0198] FIGS. 9, 10 and 11 show schematically some steps for a potential product build-up in a method according to the eleventh aspect of the present invention, wherein a macrostructure 25, for example a first material layer 20 of FIG. 8 or a relief forming material layer 2 of FIG. 3, is obtained.

[0199] A panel substrate 1 is provided. A foamable or expandable material 26 is deposited on the substrate surface 1. Preferably the foamable or expandable material 26 comprises at least one additive, such as a foaming agent, for example a blowing agent such as pentane. In a next step, an active agent 27 is deposited on the foamable or expandable material 26.

[0200] FIG. 8 shows the method wherein the active agent 27 is a foam inhibitor. In this case, upon activation of the foamable or expandable material 26 and its, preferably added, foaming agent, for example by exposure to heat, radiation and/or a laser, the active agent 27 prevents the foam formation and/or the expansion and, the optional curing at the places where the active agent 27 has been applied on the foamable or expandable material 26. On the other areas of the foamable or expandable material 26, where no active agent 27 has been applied, the foamable or expandable material 26 will foam or expand and, optionally, cure under the presence of heat and/or radiation.

[0201] FIG. 9 shows the method wherein the active agent 27 is a promotor, such as crosslinking agent or a photoinitiator. In this case, upon activation of the foamable or expandable material 26 and its, preferably added, foaming agent, for example by exposure to heat, radiation and/or a laser, the active agent 27 will allow and enhance the foam formation and/or the expansion and, the optional, curing at the places where the active agent 27 has been applied. On the other areas of the foamable or expandable material 26, where no active agent 27 has been applied, the foam formation, expansion and/or the optional curing is in this case prevented.

[0202] In a further process step, which is not shown, unreacted-unfoamed, non-expanded, or non-curedfoamable or expandable material 26 is removed, for example by suctioning, rinsing or brushing.

[0203] The present invention is in no way limited to the described and illustrated embodiments, but such methods and decorative panels may be realized in accordance with several variants without leaving the scope of the present invention.