Abstract
A method may be provided for manufacturing coated panels of the type including at least a substrate and a top layer with a motif. The top layer may be provided on the substrate. The method may involve providing a synthetic material layer on the substrate. A relief may be provided on the surface of the synthetic material layer provided on the substrate. The relief may include a pattern of recesses and/or projections. The relief may be obtained by providing a mask on or in the synthetic material layer. The mask may enable a selective treatment of the synthetic material layer. A material-removing treatment or a material-depositing treatment may be performed on the synthetic material layer, such that the mask at least partially determines the pattern.
Claims
1. A method for manufacturing coated panels of the type including at least a substrate and a top layer with a motif, the top layer being provided on the substrate, the method comprising: providing a synthetic material layer on the substrate; and providing a relief on the surface of the synthetic material layer provided on the substrate; wherein the relief includes a pattern of recesses and/or projections; wherein the relief is obtained by providing a mask the synthetic material layer; wherein the mask enables a selective treatment of the synthetic material layer; performing a material-removing treatment on the synthetic material layer, such that the mask at least partially determines the pattern; wherein the mask comprises masking portions, which are realized by means of a print; wherein the synthetic material layer is selectively solidified by means of the mask provided therein thereby rendering not or less solidified portions of the synthetic material layer; performing a material-removing treatment on the synthetic material layer to remove the not or less solidified portions of the synthetic material layer.
2. The method according claim 1, wherein the synthetic material layer is at least partially cured prior to performing the material-removing treatment.
3. The method according to claim 1, wherein the print is a digital print provided by an inkjet printer.
4. The method according to claim 1, wherein the material-removing treatment comprises at least a suction treatment.
5. The method according to claim 1, wherein the material-removing treatment comprises at least a brushing treatment.
6. The method according to claim 1, wherein the masking portions expose the synthetic material situated underneath the masking portions to a larger extent to the material-removing treatment.
7. The method according to claim 1, wherein wax or paraffin is applied for the masking portions.
8. The method according to claim 1, wherein the mask is formed in line and/or at the same time with providing the relief in the synthetic material layer.
9. The method according to claim 1, further comprising selective curing of the synthetic material layer using UV or electron beams.
10. The method according claim 1, wherein the mask is provided via a printing technique.
11. The method according to claim 10, wherein the printing technique is a digital inkjet printing.
12. The method according to claim 1, wherein the material-removing treatment is active only where the mask is present.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:
(2) FIG. 1 schematically represents some steps in a method with the characteristics of the invention;
(3) FIG. 2, at a larger scale, represents a cross-section according to the line II-II indicated in FIG. 1;
(4) FIGS. 3 to 6, at the same scale, represent cross-sections, respectively according to the lines III-III, IV-IV, V-V-, VI-VI indicated in FIG. 1;
(5) FIG. 7, at the same scale, but for a variant, represents a cross-section according to the line VII-VII indicated in FIG. 1;
(6) FIG. 8 for a variant represents a view according to the direction F8 indicated in FIG. 7;
(7) FIG. 9 schematically represents another method with the characteristics of the invention;
(8) FIGS. 10 and 11 schematically represent some more steps in a method with the characteristics of the invention;
(9) FIGS. 12 to 15 represent some more variants of a method with, amongst others, the methods of the second aspect;
(10) FIG. 16 represents another example of a method with the characteristics of, amongst others, the fourth aspect of the invention;
(11) FIGS. 17 and 18 represent other variants showing, amongst others, the characteristics of the first and the fourth aspect.
DESCRIPTION OF EXAMPLE, NON-LIMITING EMBODIMENTS
(12) FIG. 1 schematically represents some steps S1-S5 in a method for manufacturing coated panels 1. The respective coated panels 1 are of the type comprising at least a substrate 2, for example, a MDF or HDF basic panel, and a top layer 3 provided on this substrate 2. In the example, the top layer 3 is composed of a plurality of material layers 4-7, amongst which a material layer 5, which shows a motif and which, during step S2, is applied in the form of a print 8 performed directly on the substrate 2.
(13) In a previous step S1, one or more priming layers 4 are provided on the surface of the substrate 2 to be printed with the motif. These layers may have the purpose of providing a smooth subsurface and/or providing a uniform or quasi-uniform background color and/or an adhering undercoat for material layers 5-8 to be applied later, such as for the material layer 5 with the motif, or for the synthetic material layer 7.
(14) FIG. 2 represents the result of step S1 and shows that a possible uneven surface of the substrate 2 can be made flat or approximately flat by means of said one or more priming layers 4.
(15) In the example, in step S1 use is made of an application technique by means of one or more cylinders 9. It is clear that in step S1 of FIG. 1, also other application techniques may be applied for realizing one or more priming layers 4. At the same time, it is clear that it is not necessary for the invention that such priming layers 4 are applied, although this may be important for the quality of the motif. Instead of working with a priming layer 4 which is provided in liquid form, use may also be made of a priming layer 4 comprising a material sheet, such as a paper sheet, and which is provided on the substrate 2 in dry or quasi-dry form.
(16) As aforementioned, in step S2 of FIG. 1 a motif is realized by means of a print 8 which is performed directly on the substrate 2 or on a priming layer 4 already provided on the substrate 2. The obtained motif relates to a wood motif extending over the entire length of the oblong rectangular panel 1. Of course, the invention is not restricted to such motifs.
(17) In this case, for providing the printed motif use is made of an inkjet printer 10 with one or more heads. For example, use can be made of the techniques and devices which are known as such from EP 1 872 959, wherein, for example, such a battery of inkjet print heads is arranged one after the other and next to each other that the entire surface of the panel 1 can be covered by means of a multi-color print. It is evident that the present invention for step S2 neither is restricted to inkjet printing techniques, nor to motifs printed directly on the substrate 2.
(18) FIG. 3 represents the result of the print 8 performed directly on the substrate 2, in this case on a priming layer 4 already situated on the substrate 2.
(19) In step S3 of FIG. 1, an additional print 6 is provided above the printed motif. This relates to a print 6 with an expansion-preventing agent. The print 6 is performed with a pattern which will determine the final structure or the relief of the coated panel 1. Herein, the pattern covers only particular locations in the printed pattern and thus preferably does not extend over the entire surface of the final coated panel 1. In this case, the pattern forms a mask which provides the edges 11 of the panel 1 as well as certain locations 12 in the surface of the panel 1 with such expansion-preventing agent. Herein, the locations 12 in the surface of the panel 1 correspond to wood flowers or wood nerves present in the wood motif and will lead to recesses present in the final panel 1, which imitate wood pores.
(20) FIG. 4 once again clearly shows the locations 11-12 of the print 6 provided in step S3.
(21) In step S3, it is represented that the print 6, which determines the relief or the structure, is provided by means of a digital printing technique, such as by means of an inkjet printer 10. It is clear that it is not excluded that the print 6 or the expansion-preventing agent can be applied in another manner.
(22) In step S4 of FIG. 1, a synthetic material layer 7 is applied. Such synthetic material layer 7 preferably consists of a transparent or translucent matter and preferably extends over the entire panel 1 concerned. In the example, a cylinder 9 is shown for applying such layer. However, it is clear that this synthetic material layer 7 can be provided in any manner. It is also possible that in step S4 a plurality of synthetic material layers 7 situated one above the other are applied, whether or not of the same kind. Preferably, also hard wear-resistant particles are provided in the synthetic material layer 7. For example, they may be blended or woven into the synthetic material or into the synthetic material layer 7 beforehand or can be strewn into the already provided synthetic material layer 7 or deposited in another manner.
(23) FIG. 5 shows the result obtained after step S4.
(24) In step S5 of FIG. 1, a relief is provided at the surface of the synthetic material layer 7 applied in step S4.
(25) FIG. 6 represents that herein, a coated panel 1 is obtained which shows a pattern of recesses 13 and projections 14 at its surface, wherein this pattern is at least partially determined by means of the print 6 with expansion-preventing agent applied in step S3. This structure is obtained in that the synthetic material layer 7 is activated in step S5 and starts to expand. This activation may be obtained, for example, by heating the synthetic material layer 7 by means of a hot-air oven 15, an infrared oven or by radiation, such as UV or electron radiation.
(26) FIG. 6 shows that at the places where in step S3 expansion-preventing or expansion-reducing agent is applied, said expansion has occurred to a lesser extent or not at all. At those places, there are recesses 13 in the surface of the thickened synthetic material layer 7. In this way, in the example chamfers 16 have been obtained at the edges 11 of the coated panel 1, and recesses 13 have been obtained in the surface of the panel 1 for imitating wood pores 17. It is evident that the technique of the invention may also be applied for obtaining chamfers 16 only or obtaining imitations of wood pores 17 only or for obtaining other structures.
(27) FIG. 6 also shows that the obtained recesses 13 may have a structure with strong rounded portions 18.
(28) FIG. 7 shows a possibility for obtaining sharper structures. Herein, when expanding the synthetic material layer 7, in step S5 a forming mold 19 can be applied, against which the expanding synthetic material layer 7 is rising. Such technique may be of interest for forming sharper chamfers 16. In the represented example, the forming mold 19 is a substantially flat press element. However, it may also be worked with one or more press cylinders or molding wheels.
(29) FIG. 8 represents another possibility for obtaining sharper structures, such as sharp chamfers 16. Herein, the aforementioned one or more prints 6, which determine the structure, are performed with a so-called degrade, wherein the intensity or the amount of applied agent of the print 6 is varied according to the depth one wishes to obtain at that place. It is evident that this printing technique may or may not be combined with the technique represented in FIG. 7.
(30) Applying such degrade also has advantages in all aspects where the relief is at least partially determined by means of a preferably digital print.
(31) It is clear that the method of FIGS. 1 to 6 and the variants of FIGS. 7 and 8 form examples of said first and third aspect, as well as of the last-mentioned particular fifth independent aspect.
(32) FIG. 9 represents a preferred embodiment of the invention with the characteristics of the first aspect. Herein, the third possibility mentioned in the introduction is applied for this purpose. Herein, by means of a print 6, a structure is formed on a transfer element 20, in this case on a cylinder. This structured cylinder is applied for forming the relief in the surface of the coated panel 1. Forming the print 6 on the transfer element 20 is performed in line and at the same time as forming the recesses 13 or the relief in the synthetic material layer 7 of the coated panel 1. For forming the structure on the transfer element 20, preferably a digital technique, such as a printing technique by means of an inkjet printer 10, is applied, wherein, for example, lacquer or wax is deposited in a pattern on the cylinder. Further, it is represented in FIG. 9 that the structure of the cylinder can be renewed continuously in that the already used structure portion of the cylinder is removed, for example, by means of a scraping device 21, and is replaced by a newly provided structure portion. It is clear that the example of FIG. 9 also shows the characteristics of both particular independent aspects mentioned in the introduction, namely of the second and the fifth independent aspect. Also, it is clear that also in such embodiment a degrade, as described by means of FIG. 8, can be applied.
(33) FIG. 10 represents another example of a method, wherein a mask 22 is provided on the synthetic material layer 7 and subsequently a material-depositing treatment is performed on the synthetic material layer 7. Here, the material-depositing treatment relates to coating the surface of the panel 1 by means of a liquid synthetic material 23. Herein, the mask 22 is chosen such that the synthetic material 23 solely adheres to those places where the mask 22 is not provided.
(34) FIG. 11 shows the result of this method after the mask 22 and not the adhering portion of the synthetic material 23 has been removed. At the surface of the panel 1, a relief of recesses 13 and projections 14 is obtained. It is clear that this pattern is determined by said mask 22.
(35) Further, it is clear that also when applying printed masks, it may be advantageous to apply so-called degrades, such as described by means of FIG. 8.
(36) FIG. 12 represents a variant of the method represented in FIG. 9, wherein the method comprises at least the steps of providing a synthetic material layer 7 on the substrate 2 and providing in this synthetic material a relief by means of a structured mechanical press element 20. Herein, the structure of the press element 20 is formed in line and at the same time with the step of providing a relief in the synthetic material. In the example, the press element 20 relates to a roller. The difference between the embodiment of FIG. 12 and the embodiment of FIG. 9 is that now the synthetic material is provided with the relief prior to providing the structured synthetic material layer 7 on the panel 1. Namely, the synthetic material is provided on an already structured portion of the press element 20 and the thus formed synthetic material layer 7 is at least partially transferred onto the panel 1.
(37) FIG. 13 represents another variant hereof, wherein for the press element 20 instead of a roller, a press belt or press web is used, which is transported over rolls 24 towards the panel 1. The press element 20 is of the type which can be provided on a supply roll 25. This may relate, for example, to a foil, such as a synthetic foil, a paper sheet or a metal sheet, such as aluminum foil. In dashed line 26, it is represented that one may also work with an endless belt, wherein then preferably also a scraping device 21 is provided, such that an already applied structure portion can be removed. In the case of such endless belt, for example, a metal belt may be used.
(38) Of course, the arrangement of FIG. 13 may also be applied when, as it is the case in the example of FIG. 9, the synthetic material is provided on the panel prior to realizing the relief in the synthetic material layer 7. FIG. 13 also represents that it is possible to perform a forced drying on the synthetic material layer by means of any drying station 27. As a drying station 27, for example, a hot-air oven, a UV heating element or an infrared heating element may be applied.
(39) It is noted that it is possible to structure the press element 20 of FIG. 13 at the other side 28 and obtain a similar effect. Such embodiment is not represented here, however, it has the advantage that the risk is minimized that the print 6 partially is also transferred onto the panel 1.
(40) The arrangement represented in FIG. 13 corresponds to the arrangement represented in document WO 2007/059667, however, with the difference that instead of a previously structured material web, a press element 20 or press web structured in line and at the same time is applied.
(41) FIG. 14 represents another embodiment wherein this risk is minimized. Herein, substantially the process represented in FIG. 12 is applied, however, with the difference that a foil 29 is applied between the press element 20, which press element is structured in line and at the same time. This foil 29 is deformed by means of the structured press element 20, as a result of which a structure of recesses 13 and projections 14 is obtained in the underlying synthetic material layer 7.
(42) It is also noted that the embodiments of FIGS. 13 and 14 have the advantage that only the web-shaped press element 20, the foil 29, respectively, come into contact with the synthetic material of the synthetic material layer 7. This is particularly advantageous when such synthetic material layer 7 comprises wear-resistant particles, such as aluminum oxide. In this manner, namely, the remaining parts of the arrangement, such as the rollers 24, are kept free from rapid wear.
(43) FIG. 15 represents another embodiment similar to the example of FIG. 12, wherein, however, the print 6, which determines the structure or at least a part thereof, is transferred onto the synthetic material layer 7. The technique of FIG. 15 possibly may be applied for forming a mask 22, which can be applied, such as described in the introduction in reference to the fourth aspect.
(44) FIG. 16 represents another example of a method with the characteristics of, amongst others, the fourth aspect of the invention. Herein, a mask 22, which initially had been provided on the synthetic material layer 7, is printed into the synthetic material layer 7 by means of press treatment prior to applying said material-removing and/or material-depositing treatment. In this case, this relates to a material-removing treatment, namely, a brush treatment S6. Possibly, a drying treatment may be applied on the synthetic material layer 7 prior to said material-removing treatment, such that the actual synthetic material layer 7 is sufficiently resistant against this treatment S6. Such drying treatment is not represented here, however, may be understood as being similar to that of the drying station 27 of FIG. 13.
(45) FIG. 17 represents another example of a method with, amongst others, the characteristics of the fourth aspect. Herein, the mask 22 is of the type wherein the masking portions provide for that the synthetic material of the synthetic material layer 7, which is situated there underneath, is exposed to a larger extent to the material-removing treatment of the step S6, in this case, a suctioning treatment. In the example, this is realized in that the masking portions 30 comprise a material which is impermeable or at least offers a certain protection for the UV radiation of the drying station 27, such that the portion 31, situated there below, of the synthetic material layer 7 is solidified less or not at all. Those portions 31 of the synthetic material layer 7 then are removed in step S6, in this case, together with the mask 22, by means of the suctioning treatment represented here. It is possible that the mask 22 is removed in a separate step, preferably prior to removing the not or less solidified portions 31 of the synthetic material layer 7.
(46) It is clear that the mask 22 from the example of FIG. 17 may be realized by means of a possible digital print 6, wherein then also an embodiment of the first and possibly the fifth aspect of the invention is obtained.
(47) FIG. 18 represents an example in which a mask 22 is used, which is made as an entity existing as such. In this case, the mask 22 is composed of a substantially translucent or transparent foil 29, which, by means of a print 6, is provided with masking portions 30. In the example, this, as it is the case in FIG. 17, relates to masking portions 30, which provide for that portions 31 of the synthetic material, which are situated underneath the masking portions 30, are exposed to a larger extent to the material-removing treatment of the step S6, in this case, a suction treatment. This foil 29 is provided between the radiation source, in this case, the drying station 27, and the synthetic material layer 7 in a step preceding the material-removing treatment, at which location the masking portions 30 form a selective screen, for example, for UV radiation emitted by the drying station. FIG. 18 also represents an example of a method wherein the mask 22 is removed from the synthetic material layer 7 in a separate step. In this case, this is performed by moving the foil 29 away from the synthetic material layer 7 before the not at all or less solidified portions 31 are exposed to the material-removing treatment of step S6.
(48) It is clear that the masking portions 30 may be provided on any side of the foil 29, or may even be provided on both sides thereof. The represented embodiment has the advantage that the masking portions 30 can be removed from the synthetic material layer 7 more simply. Possibly, the side of the foil 29 which is in contact with the synthetic material layer 7 may be provided with a release layer, for example, with a release layer comprising silicone and/or Teflon.
(49) It is clear that the embodiments of FIGS. 17 and 18 also form an example of a method wherein the mask is formed in line and at the same time with the step of providing the relief in the synthetic material. Herein, then in fact another masking portion 31 is applied when providing the relief than the one formed at the same moment by means of the inkjet printer 10.
(50) According to a not-represented variant, a plurality of masks 22 can be provided one after the other and/or above each other. In the example of FIG. 16, 17 or 18, a further mask 22 can be applied before or after an earlier mask 22 is printed into the synthetic material layer 7 by means of said press treatment, or after said mask 22 has been removed already. By a good choice of the various masks 22, recesses 13 and/or projections 14 may be realized with oblique walls and/or different depths.
(51) It is clear that the results of the methods according to the invention depicted in FIGS. 6, 7 and 9 to 18 can be finished even further with one or more finishing layers, such as lacquer layers and the like.
(52) It is noted that the thickness of the material layers and substrates represented in FIGS. 2 to 7 and 9 to 18 is represented only schematically and does not comprise any restrictions. However, it is clear that the thickness of the top layer can be restricted to several tenths of millimeters, whereas the thickness of the substrate may vary from 5 to millimeters or thicker.
(53) It is important to note that according to all aspects of the invention relatively rigid panels are manufactured and no coverings that can be rolled up. Rigid panels have the advantage that they can easily be provided with connection means, for example, screws, dowels or mechanical coupling means, which allow that two of such panels, for example, floor panels, can be coupled to each other, for example, by milling the profiles of such coupling means into said substrate. Such coupling means and milling techniques are known as such from WO 97/47834 or DE 20 2008 008 597 U1. Due to their rigidity and the presence of coupling means, the manufactured coated panels are simple to install and require no gluing to the underlying layer.
(54) The present invention is in no way limited to the embodiments described above; on the contrary may such methods and panels be realized according to various variants, without leaving the scope of the present invention.
