EP3539792A1 - Method for creating structures on a substrate - Google Patents

Abstract

The invention relates to a method for producing structures on a substrate. In order to provide a quick and inexpensive method of fabricating structures on a substrate, a method is provided which includes the steps of: placing a decor provided with a pattern, scanning the decor and structure in separate files, printing the decor a substrate, printing the structure onto a pattern-forming film, embossing the structure by means of the pattern-forming films on a substrate provided with the decoration, if necessary Optimizing the structure and re-printing the structure on a pattern-forming film and embossing the structure by means of the pattern-forming film on a provided with the decor substrate, transferring the possibly optimized structure on a embossing plate.

Description

The invention relates to a method for producing structures on a substrate.

The production of structures on a substrate, in particular on paper or wood-based surfaces is known per se. For example, this describes EP 2 179 863 A1 the decorating, but also the structuring of a substrate by means of a pattern-forming film. This method is well suited for small quantities, but for bulk products, the costs of the pattern-forming film are too high.

The object of the invention is to propose a flexible method for producing structures on a substrate, which is suitable for both small and large numbers.

This object is achieved by a method according to claim 1.

• das Vorlegen eines Dekors, das mit einer Struktur versehen ist,
• das Scannen des Dekors und der Struktur und das Speichern in separaten Dateien,
• das Drucken des Dekors auf ein Substrat,
• das Drucken der Struktur auf eine Strukturgeberfolie,
• das Prägen der Struktur mittels der Strukturgeberfolien auf ein mit dem Dekor versehenes Substrat,
• ggf. das Optimieren der Struktur und erneutes Drucken der Struktur auf eine Strukturgeberfolie und Prägen der Struktur mittels der Strukturgeberfolie auf ein mit dem Dekor versehenes Substrat und
• das Übertragen der ggf. optimierten Struktur auf ein Prägeblech.

The solution according to the invention provides a method in which the following steps are provided for producing structures:

• the presentation of a decoration provided with a structure
• scanning the decor and structure and saving them in separate files,
• the printing of the decoration on a substrate,
• the printing of the structure on a pattern-forming film,
• the embossing of the structure by means of the structuring donor sheets on a decorated substrate,
• if necessary, optimizing the structure and re-printing the structure onto a pattern-forming film and embossing the structure by means of the pattern-forming film onto a substrate provided with the decoration and
• the transfer of the optionally optimized structure on a embossing plate.

With the method according to the invention, the structure to be transferred to the substrate can first be transferred to the substrate quickly and inexpensively by means of pattern-forming film. The structure can be optimized if necessary, details are explained below. In this way, patterns or smaller jobs for the substrate can be created in a simple manner by means of texturing film quickly, easily and at low cost. In particular, the fast and inexpensive production of patterns allows z. As customers or sales staff, decor and structure to review and suggestions for improvement also to test or test until the desired optimum is reached.

When the desired optimum is achieved and when decor and structure are to be produced in larger quantities, the optimized structure is transferred to a press plate and transferred from the press plate to the substrate. Thus, the more economical in this case press plate, preferably a press plate made of stainless steel is used for the larger amounts. The risk that the structure could not fit when first producing the press plate, is excluded by the described flow. The file storing the optimized structure is used to make the press plate. This ensures that the optimized structure is also used reliably for the production of large quantities of a substrate, which is provided with a decor and with a structure. At the same time, press plates are only produced if the structure is actually in demand and it is ensured that there is sufficient demand to justify the production of a cost-intensive press plate. This not only better allocates costs and thereby reduces overall, but also fewer press plates are in stock, which simplifies storage.

Decor and structure are advantageously coordinated, especially in decors and structures that mimic natural materials such as wood or stone.

According to a further advantageous embodiment, an optimization of the structure, in particular to vote on the decor, take place. The optimization takes place when the structure does not yet meet the requirements by changing the structure, either directly on the computer by editing the file or by the edited structure is edited and rescanned, then saved as a new file and then a new template film is produced with the changed structure. This modified structure is then reprinted onto a substrate provided with the associated decor and reassessed. Possibly. the steps of optimizing are repeated. Similarly, according to a development of the invention, the decor on the substrate can be optimized by the decor either on the computer changed by editing the file or a printed decor is rescanned, and is saved as a new file to then printed on the substrate to become. Printing is preferably done with digital printers, e.g. As laser or inkjet printers.

The patterning film is preferably made by printing by adding a patterning medium, e.g. As ink, pigments or particles are applied by means of a printer on a film. The structuring medium may preferably be used in a digital application device, e.g. As a 3D printer, a laser printer or an inkjet printer are processed. The medium can be processed as a solid or in liquid form. The structure-giving medium is preferably applied by means of a digital printer, in particular an inkjet printer, a laser printer, a 2-D or 3-D printer in solid or liquid form. The medium is applied to the pattern-forming film and bound there. It forms a structure there, which means that the medium is applied not only as a layer on the surface of the pattern-forming film, but as an elevation, which projects beyond the surface of the film. In contrast to a two-dimensional decor creates a three-dimensional structure that, depending on the type of medium used, still dry, set or harden, z. B. by the action of temperature or radiation such as laser or UV light or electron radiation. It has surprisingly been found that the structure applied to the embossing side of the structuring film is sufficiently strong to emboss the surface of a substrate.

The height of the structure may preferably be from 1 μm to 1000 μm. It can vary to replicate a given model in detail. The minimum height results from the minimum application quantity of the structure-giving medium, which is the application device The maximum application height is determined by the maximum embossing that can be introduced into the surface of the substrate. For example, repeating patterns or individual images (silhouettes of people, objects or areas such as city silhouettes), but also replicas of natural objects such. As wood grain, bark imitations or pictures of plants can be applied as a structure on the pattern forming film.

As a rule, the structure is applied to the structure-forming film on the basis of a digital data record. It is advantageous that e.g. in lifelike reproductions of wood grains of the same digital data set, which is used for the manufacture of the structure, can also be used to decorate a decorative film, eg. B. to print a paper foil or a plastic film with a two-dimensional decor in color. After or before the decoration is produced, the corresponding structure is printed on the film with the identical data record. In this way, substrates can be made uniform, z. For example, a decorative film or decorative paper can be laminated onto the substrate, then either the decorative film or a further coating which is applied to the decorative film can be provided with a three-dimensional structure by means of the pattern-forming film.

Due to the simple and inexpensive production of the pattern-forming film by means of a digital application device, a film for single use or a reusable film can be produced. Thus, samples, individual orders and small series can be produced economically.

Depending on the resolution of the digital application device, a high-resolution structure can be generated. Thus details of the structure can be applied in a resolution of 25 dpi to 4800 dpi. By the digital application device, the structure-giving medium can be applied very differentiated and finely distributed in different thickness on the printing side of the pattern-forming film. The three-dimensional structure, which is produced on the printing side of the pattern-forming film, can be applied with different thicknesses, based on the surface of the printed page, from about 1 .mu.m to about 1000 .mu.m, so that pronounced relief-like structures are applied which are tactilely perceptible on the surface of the substrate.

The texturing film can be chosen from a variety of materials. The texturing film can z. B. made of metal, especially aluminum. It can also be made of plastic, paper, cardboard or a composite material. It can be designed in one or more layers. If the texturing film is made of plastic, it preferably has one or a combination of the following plastics: polyethylene, high density polyethylene, polypropylene, polyethylene terephthalate, polyurethane, thermoplastic polyurethane, polyacetate, polycarbonate, polyimide, polystyrene, polyvinyl chloride or polytetrafluoroethylene. For the preparation of the pattern-forming film and mixtures of the aforementioned materials can be used, for. B. mixtures of different plastics or layers of different materials. Optionally, the pattern-forming film may also have a coating, for. As a paint or a primer. For example, the coating can improve the adhesion of the structure-imparting medium to the pattern-forming film, or it can influence the surface property of the pattern-forming film, for example, B. allow a matte or glossy surfaces.

At least the printing side of the pattern-forming film may have a matt or glossy to high-gloss surface. Accordingly, the print side creates a dull or glossy or glossy surface on the substrate.

As already described above, a solid or liquid medium z. B. by a 3D printer, a laser printer or an inkjet printer applied to the printing side of a film, which is the pattern-forming film. The structuring medium intimately bonds to the print side of the film so that it will adhere completely to the print side during embossing and also during removal of the patterning film from the substrate. This can be z. B. done by the structure-giving medium adheres by drying on the pressure side, for example by water or solvent evaporates. Alternatively, the medium can harden when z. B. form by the action of temperature and / or radiation polymers or solid particles with each other and / or connect to the pressure side of the pattern forming film, for example, weld, fuse or glue. Typically, a through a 3D printer processed medium in the form of solid particles applied and z. B. sintered by laser radiation, UV radiation or other radiation to a solid structure, fused or welded. If the medium is applied in liquid form, it often contains monomers or oligomers or solid particles, which then likewise polymerize under the action of radiation, are sintered or glued or welded. If the liquid medium consists exclusively of a substance which is used to produce the structure, the otherwise necessary removal of the solvent or water is eliminated. Structure-providing media, either in liquid form referred to as inks or as solid particles are known per se.

The applied to the print side structure, which is imprinted after embossing in the surface of the substrate as a negative, can either be a self-contained motif, but it can also reproduce a motif multiple times or they can only reproduce the part of a motif. Typically z. B. wood structures or other natural structures such. B. stone structures shown. It can also be any other motifs such. As logos, skylines or the like can be produced.

Advantageously, regardless of the subject further information is applied to the print page, z. As print marks or other information relating to the alignment of the pattern forming film relative to the substrate or a press in which the patterning film and the substrate are pressed to transfer the structure to the surface of the substrate. This information can also, since they are transferred to the surface of the substrate, be used for subsequent processing steps of the substrate, for. B. to give instructions for dividing the substrate into individual parts. This further information may also be applied by the digital applicator or may be applied by other applicators.

The application of a structure to the surface of a substrate comprises the steps of providing a substrate having a surface and providing a pattern-forming film having a printing side, to which at least portions of a structuring medium is applied which forms a structure. Furthermore, the method comprises placing the printing side of the pattern-forming film on the surface of the substrate and pressing the substrate and pattern-forming film in a press, wherein the Structure, which is applied on the printing side of the structure-forming film, imprinted into the surface of the substrate, since in the press smooth, non-structured press plates are used. Thus, the medium imparting the structure applied to the printing side of the pattern-forming film comes into direct contact with the surface of the substrate in order to produce there a negative of the structure applied on the printing side. The surface of the substrate is embossed according to the invention relief and thus also shows a structure.

In the simplest case, only the pressure of the press is required to impress the structure into the surface of the substrate. The pressure is usually from 10 N / mm ² to 1000 N / mm ² . In most cases, however, an elevated temperature is also used, so that the surface of the substrate is better deformable. The temperature is z. From 40 ° C to 300 ° C, preferably from 140 ° C to 200 ° C.

The pressure is applied by a press, usually a short-cycle press (KT press) or by a continuous press. As a rule, a pressing time of a maximum of 150 seconds is sufficient, usually 10 seconds to 30 seconds, at least a pressing time of 5 seconds is sufficient to image the structure on the printing side of the pattern-forming film as negative, and thus also as a structure on the surface of the substrate , The pressing conditions are chosen depending on the substrate to be embossed. Optimal press conditions determined by the expert with a few exploratory experiments.

Suitable substrates are all materials which can be embossed by the pattern-forming film, typically wood or wood-based materials, plastics, in particular thermoplastics, metals, in particular metal foils, but also ceramic materials. Wood fiber or chipboard, plywood, laminated wood and OSB boards are among the wooden materials that are referred to in the context of the invention as wood-based materials. The materials can also be used as an intermediate, for. B. before or during drying, pressing or curing when they are in a manufacturing state in which they are still soft enough to be embossed. The materials can also be heated for embossing the surface or otherwise softened temporarily to allow embossing of the surface.

According to an advantageous development of the invention, the substrate has a surface coating which is embossed by the pattern-forming film. This surface coating, which then forms the surface of the substrate, may preferably consist of a lacquer or a synthetic resin. Lacquer or synthetic resin can advantageously be highly viscous or dried, but not yet cured. Also, gelled paints, z. B. UV or radiation-curing coatings can be embossed in a simple manner by the pattern-forming film, so that the surface coating as a structure shows an exact and detailed negative of the applied to the printing side of the pattern forming film structure.

Typical synthetic resin coatings may well be suitable as a surface coating of a substrate in order to be pressed with the pattern-forming film according to the invention, in particular if the press is operated at a pressing temperature of about 140 ° C. to about 200 ° C. The synthetic resin is preferably used as a precondensed or dried but not yet cured surface coating z. B. used by wood-based panels. It liquefies in the press at the temperatures mentioned. In this state, it can be embossed by the pattern-forming film. In the course of the pressing process, the resin cures at the temperatures mentioned, so that a permanent structure can be embossed into the surface. Typical synthetic resins are melamine resin, phenol-formaldehyde resin and urea resins.

But paints can be used without further ado. Commonly used lacquers are acrylate- or metacrylate-based lacquers, polyurethane lacquers, epoxy lacquers, or water-based lacquers. Preference is given to using UV- or radiation-curing lacquers and also thermally curing lacquers, because these lacquers can be gelled (partially hardened) to match the pattern-forming film according to the invention, so that after the pressing process an optimal reproduction of the structure of the pattern-forming foil in the lacquer surface is mapped, e.g. , B. because the paint is no longer bleeding. During the pressing process or afterwards, the varnish can be fully cured.

It has been found that there is sufficient demand for a structure so that it is economical to manufacture a metal press plate, especially stainless steel To use the structure, the file with the possibly optimized structure for producing a press plate is used and the thus structured press plate is used instead of a non-structured press plate in the press. Now, to produce a larger amount of a patterned, decorated substrate, only the decorated substrate is transferred to the press and stamped by closing the press. The conditions during pressing (time, pressure and temperature) are usually the same as when embossing the structure by means of structuring film.

Fig. 1

ein Ablaufschema des erfindungsgemäßen Verfahrens

Details of the method according to the invention will be explained in more detail with reference to an exemplary embodiment. It shows:

Fig. 1

a flow chart of the method according to the invention

As in Fig. 1 illustrated, the inventive method begins to submit a provided with a structure decor, z. As a wood or stone surface or an artificially designed surface. Then the decor and then the structure are scanned and stored in separate files. The resolution can range from 25 dpi (dots per inch) to 4800 dpi.

The decor is based on the data stored in the respective file on the substrate, for. As a decorative paper or the surface of a wood-based panel, in particular a wood-based panel with a resin layer applied thereto, printed. For this purpose, a digital printer, z. As a laser printer or an inkjet printer used. At the same time, the structure stored in the respective file is printed on a structure-forming foil. The texturing film is made of a plastic, here PET (polyethylene terephthalate). However, it can be made from a wide range of materials including various plastics, metal, paper, cardboard or composites. The suitable plastics are listed in the general description. The application of the structure to the pattern-forming film by means of a digital printer, z. As a laser or inkjet printer, the structures imprinted in a thickness of 1 .mu.m to 1000 .mu.m on the PET film. The ink or other media applied by the printer adheres firmly to the film and is of a density suitable for embossing a substrate with a decoration applied thereto.

Subsequently, the structure is embossed by means of the pattern-forming film on the provided with the decor substrate. For this purpose, a stack of pressed material from the substrate, which is provided with a decor, and the pattern-forming film is introduced into the press. The substrate in the present case is an 8 mm fiberboard and the decor is applied as a resin impregnated decor paper on an upper side of the fiberboard. The pressed material stack is pressed between smooth, non-structured press plates. Embossing is preferably carried out in a short-cycle press (KT press). In the simplest case, only the pressure of the press is required to impress the structure into the surface of the substrate. The pressure is usually from 10 N / mm ² to 1000 N / mm ² . In the present case, however, an elevated temperature is additionally used so that the surface of the substrate is better deformable. The temperature is usually in a range from 40 ° C to 300 ° C, preferably from 140 ° C to 200 ° C, in this case at 160 ° C.

If the decor and the structure are-as in the present embodiment-coordinated, then after a first pressing of the structure on the decor to check whether the structure and the decor are optimally matched. In addition, it must be checked whether the structure originally removed from the original in the pressed version is also optimal or whether there is still a need for optimization, eg. As in the color, in the precision of the vote on the decor or the arrangement and execution of the structure in terms of the depth of the embossing. The same applies to the decor. Even if the decor seemed to be well suited as a template, it should be checked in the finished pressed version if there is any further need for optimization. As in the adjustment of the coloring, the improvement of shades or the sharpness of the contours.

After this optimization requirement has been determined, the files for the structure and the decor are revised and adjusted according to the need for optimization, if the changes can be made directly to the file by means of a computer. If not, a printout of the structure and / or decor is printed, edited, and rescanned so that there is a changed file each time. The structure is reprinted onto a patterning sheet according to the adjusted file and pressed onto a decorative substrate as described above. Is the decor has also been adjusted, the customized decor is previously printed on the substrate, so that it can be checked whether the modified version of the structure and possibly the decor fit together. This process can be repeated until the result is satisfactorily optimized. It is obvious that the production of a pattern-forming film is quick and uncomplicated and much cheaper, even in relation to small sample press plates of about 50 cm x 50 cm.

Trial prints and small individual orders can be produced solely using the pattern-forming film. On the other hand, larger amounts of patterned substrates can be made more economically by using a structured press sheet. According to the invention, the optimized file is used to produce a structured press plate, so that even large quantities of a substrate provided with a structure can be produced economically.

In this way not only the costs of producing structured substrates are reduced. According to the invention, structured press plates are only produced if it is actually economical, whereas previously it had to be speculated whether the production of a specific structured press plate would be economically viable. At the same time, the storage of structured press plates is much easier because only such press plates are made, which are actually required for the production of large quantities of structured substrates.

Claims (9)

Method for producing structures on a substrate with the steps: Presenting a decoration which is provided with a structure Scanning the decor and the structure and saving the decor and structure in separate files, Printing the decoration on a substrate, Printing the structure onto a pattern-forming film, Embossing of the structure by means of the structuring donor sheets on a decorated substrate, if necessary, optimizing the structure and re-printing the structure onto a pattern-forming film and embossing the structure by means of the pattern-forming film onto a substrate provided with the decoration, Transferring the possibly optimized structure to a embossing plate. A method according to claim 1, characterized in that the structure is applied to a pressure side of the pattern-forming film, and that the structure, with respect to the pressure side, a height of 1 .mu.m to 1000 .mu.m. A method according to claim 1 or 2, characterized in that the structure has a resolution of 25 dpi up to 4800 dpi. Method according to at least one of the preceding claims, characterized in that the pattern-forming film is made of metal, plastic, paper, cardboard or a composite material. A method according to claim 4, characterized in that a structuring film is used which comprises aluminum, polyethylene, high density polyethylene, polypropylene, polyethylene terephthalate, polyurethane, thermoplastic polyurethane, polyacetate, polycarbonate, polyimide, polystyrene, polyvinyl chloride or polytetrafluoroethylene or a combination of these materials. Method according to at least one of the preceding claims, characterized in that the pattern-forming film has a matt, a glossy or a high-gloss print page. Method according to at least one of the preceding claims, characterized in that a stainless steel sheet is used as the structural sheet. Method according to at least one of the preceding claims, characterized in that the optimization takes place several times. Method according to at least one of the preceding claims, characterized in that the decor is optimized.

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