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EP4124467A1 - Un procédé de fabrication d'un panneau - Google Patents

Un procédé de fabrication d'un panneau Download PDF

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Publication number
EP4124467A1
EP4124467A1 EP21188714.6A EP21188714A EP4124467A1 EP 4124467 A1 EP4124467 A1 EP 4124467A1 EP 21188714 A EP21188714 A EP 21188714A EP 4124467 A1 EP4124467 A1 EP 4124467A1
Authority
EP
European Patent Office
Prior art keywords
substance
layer
additional
foil
discrete quantities
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21188714.6A
Other languages
German (de)
English (en)
Inventor
Bruno Vermeulen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin BV
Original Assignee
Flooring Industries Ltd SARL
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Flooring Industries Ltd SARL filed Critical Flooring Industries Ltd SARL
Priority to EP21188714.6A priority Critical patent/EP4124467A1/fr
Publication of EP4124467A1 publication Critical patent/EP4124467A1/fr
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B44C3/025—Superimposing layers to produce ornamental relief structures

Definitions

  • Known methods for manufacturing said panels comprise the step of providing said top layer in the form of a sheet, normally a thermoplastic sheet or a melamine impregnated sheet.
  • Said sheet can comprise a pre-formed surface structure for providing the surface of the panel of a three-dimensional relief.
  • the structure on the sheet is obtained by embossing plates or rollers that have to be previously prepared.
  • embossing technique is so expensive that is convenient only for high volume production batches and is also quite rigid and limited in the variety of the design.
  • the curable substance may comprise a synthetic resin which is polymerized during the radiation treatment, more specifically via free radical polymerization. Radiation generates radicals in the curable substance. Since the chemical affinity between a radical and oxygen is higher than the affinity of the radicals with each other inert conditions are advantageous.
  • the radiation may be UV radiation, X-ray radiation, laser radiation, electron beam radiation, visible light, infrared, or the like. If curing is performed by means of UV light the curable substance may contain photo initiators for initiating free radical polymerization. In particular, mercury-free UV LEDs appear to be appropriate because of their advantageous penetration characteristics into the curable substance. In case of using electron beam radiation photo initiators are not required.
  • the curable substance may be applied by means of inkjet printing, screen printing, roller printing, spraying, curtain coating or the like.
  • the curable substance is applied by means of coating techniques, preferably roller coating, in order to apply higher quantities of curable substance than those applicable through printing technique.
  • coating techniques preferably roller coating
  • the curable substance may be a liquid, or a pasty substance.
  • the characteristics of the air-tight foil correspond to the type of radiation that is used.
  • the foil may be transparent, wherein transparent means that it is transparent for the radiation used for curing, for example in case of UV curing it is transparent for UV radiation, but may be opaque for visible light. In case of applying electron beam radiation the foil should be transparent for electron beam radiation. Since the foil is removed after the step of curing the colour of the foil is of less relevance for the esthetical properties of the final product.
  • the foil may be made of thermoplastic material, for example PVC.
  • the substrate may be rigid or flexible such that the resulting panel is rigid or flexible, respectively. It may be made of wood-based material like MDF, HDF, or thermoplastic, preferably vinyl, for example WPC, SPC or LVT, metal, glass, stone, ceramic, textile, non-woven fabric, polymeric composite, mineral-based material like MgO, or the like. Furthermore, although less preferred, the substrate may be a flexible thin sheet such that the resulting product itself can be an intermediate product that can be attached to a second substrate.
  • the resulting panel may be suitable for a floor, wall or ceiling covering or alternative coverings.
  • the product may also be a panel that is suitable for furniture, or the like.
  • the discrete quantities of an additional substance are applied onto the layer of curable substance before applying the foil onto the layer of curable substance including the discrete quantities of an additional substance, wherein attractive force between the discrete quantities of an additional substance and the foil is greater than between the discrete quantities of an additional substance and the layer of at least partly cured substance.
  • the step of applying the discrete quantities of an additional substance may comprise a digital printing technique, for example inkjet printing. This provides the opportunity to print the discrete quantities of an additional substance in numerous different possible patterns and to control the penetration depth of the discrete quantities of an additional substance into the layer of curable substance.
  • the discrete quantities of an additional substance are applied to the foil. This provides the opportunity to apply the discrete quantities of an additional substance to the foil before or after applying the foil onto the layer of curable substance.
  • the discrete quantities of an additional substance are applied onto the foil after applying the foil onto the layer of curable substance, wherein the discrete quantities of an additional substance allow less transmission of the radiation than the foil.
  • the discrete quantities of an additional substance do not penetrate into the layer of curable substance, but portions of the layer of curable substance located directly below the respective discrete quantities of an additional substance remain uncured or become partly cured. This provides the opportunity to treat these portions separately after removing the foil and the discrete quantities of an additional substance from the layer of at least partly cured substance in order to create a different appearance at these portions.
  • the discrete quantities of an additional substance may be applied to the foil by means of digital printing, for example by means of inkjet printing. In this case the discrete quantities of an additional substance are fixed to the foil.
  • the layer of curable substance is partly cured during the step of curing, wherein after the step of removing the foil and the discrete quantities of an additional substance the layer of partly cured substance is treated by means of a step of additional radiation curing. Consequently, the whole layer of curable substance including the mentioned uncured portions is cured by means of radiation resulting in a layer of cured substance.
  • the uncured portions may only be upper portions of the layer of partly cured substance at a surface thereof which is directed away from the substrate, wherein the depths of the upper portions in the layer of partly cured substance are smaller than half of the thickness thereof. Hence, the uncured upper portions are relatively shallow.
  • the step of additional radiation curing may comprise radiation by means of an excimer lamp.
  • An excimer lamp has a low penetration depth of UV radiation such that a polymerization process in shallow uncured regions can be performed at a relatively low energy consumption level. This leads to a superficial polymerization, which causes a volume shrinkage, which in turn manifests itself in surface folds of varying degrees. This deformed "skin" leads to a diffuse reflection of the light, which is perceived as a matt effect.
  • the mentioned low penetration depth is particularly advantageous in case of the presence of shallow uncured portions of the layer of partly cured substance.
  • the method may comprise the step of providing the panel with a decorative layer.
  • the decorative layer can be preferably provided between the substrate and the curable substance so that the curable substance forms a protective layer, also called wear layer, on top of said decorative layer.
  • Said decorative layer may comprise a pattern, for example imitating a wood, a stone or a cement material.
  • the decorative pattern is printed directly onto the substrate by means of inkjet printing. More preferably, it is printed with an inkjet printer that is disposed upstream to a device for providing the curable substance. With the expression "printed directly” it is meant that the printing operation is performed on the substrate instead of being performed on a separate material, like a sheet, that is afterward provided on the substrate.
  • the expression "printed directly” doesn't exclude that intermediate layers, like primers or ink receiver layers, are interposed between the surface of the substrate and the decorative layer.
  • the decorative layer is in form a separate layer, for example a decor sheet, that is attached on top of the substrate for example by gluing, thermal lamination or lamination.
  • the decorative layer can be printed using water-based inks, solvent based inks, oil based inks or, preferably, UV curable inks.
  • the discrete quantities of an additional substance can be applied in a pattern which is in register with the decorative pattern. This results in a surface texture which is in register with the decorative pattern. Thanks to the fact that the structure is not preformed on a separate sheet, it is possible to obtain an extremely precise synchronization of the decorative pattern and of the relief. Moreover, this high precision synchronization can be obtained for an increased variety of the decor, without the need of a huge stock of preformed structured sheets.
  • the curable substance can be transparent or translucent, in particular after the curing step.
  • the transparency of the curable substance is preferably refereed to the visible radiation so that the curable substance may be visibly transparent and the decorative layer is visible through the curable substance.
  • the curable substance is a waterbased substance.
  • the curable substance may comprise acrylic acid esters or methacrylic acid esters which can be polymerized by a free radical mechanism by actinic radiation and which are present, on their own or together, in a polymerizable mixture.
  • a component may be a mono- or polyfunctional prepolymer, i.e. a mono- or polyunsaturated prepolymer.
  • the copolymerizable mixture contains, if appropriate, a further component having a diluting action, which is described as a diluent monomer or diluent oligomer.
  • the components used have a strong tendency to polymerize by a free radical mechanism under the action of actinic radiation.
  • Suitable actinic radiation is a light in the near UV region or high-energy radiation, for example electron, particle or x-ray radiation.
  • a prepolymer which can be polymerized by free radical mechanism is a polyfunctional, unsaturated aliphatic or aromatic acrylate or methacrylate, preferably an unsaturated polyester acrylate oligomer and especially an aliphatic urethane acrylate oligomer or aromatic urethane acrylate oligomers.
  • a mono-, di-, tri-, tetra-, penta- or hexaacrylate or - methacrylate may be used as an additional suitable monomer or oligomer in the mixture which can be copolymerized by a free radical mechanism.
  • These mono- to hexaacrylates or mono- to hexamethacrylates are esters of polyols having 1 to 6 OH groups with acrylic acid or methacrylic acid, respectively, and are therefore also known as polyol acrylates or polyol methacrylates, respectively.
  • Suitable diacrylates are esters of acrylic acid with aliphatic, dihydric alcohols, in particular ethylene glycol, 1,2-propylene glycol, 1,3-propyleneglycol, butane diols, 1,6-hexane diol or neopentylglycol, with aliphatic ether-alcohols, in particular diethylene glycol, dipropylene glycol, dibutylene glycol, polyethylene glycols or polypropylene glycols, with oxyalkylated compounds of the above-mentioned aliphatic alcohols and ether-alcohols or with aromatic dihydroxy compounds, in particular bisphenol A, pyrocatechol, resorcinol, hydroquinone, p-xylyleneglycol or p-hydroxybenzyl alcohol.
  • aliphatic, dihydric alcohols in particular ethylene glycol, 1,2-propylene glycol, 1,3-propyleneglycol, butane diols, 1,6
  • Preferred diacrylates are 1,6-hexanediol diacrylate, dipropyleneglycol diacrylate, acrylic acid 2-(2-vinyloxy-ethoxy)-ethyl ester, propoxylated neopentylglycol diacrylate, isobornyl acrylate, mono-2acrryloyloxyethyl phtalate, tricyclodecane dimethanol diacrylate, 2-carboxyethyl acrylate, Benzyl acrylate, tripropylene glycol diacrylate and 1,4-butanediol diacrylate.
  • Preferred triacrylates are trimethylolpropane triacrylate and pentaerythritol triacrylate.
  • suitable polyfunctional prepolymers are also epoxyacrylate and silicone-acrylate oligomers, which are preferably used together with the diacrylates or triacrylates mentioned in the mixture which can be copolymerized by a free radical mechanism.
  • the prepolymers are compounds known per se and are prepared, for example, from hydroxylated copolymers in which the hydroxyl groups are distributed statistically along the copolymer chain.
  • Statistically unsaturated acrylic copolymers are obtained from this copolymer by esterifying the hydroxyl groups with acrylic acid.
  • Semi-terminal unsaturated acrylic copolymers are prepared by having the hydroxyl group at the end of the chain in the preparation of the hydroxylated copolymers.
  • Urethane acrylate oligomers are prepared by reacting (meth)acrylic acid esters containing hydroxyl groups, for example, hydroxyethyl methacrylate, with polyfunctional isocyanates, preferably diisocyanates.
  • the diisocyanates or polyisocyanates can preferably be reaction products of diols, polyether-diols or polyester-diols containing a stoichiometric excess of monomeric diisocyanate or polyisocyanate.
  • the polyfunctional prepolymer preponderates in the polymerizable mixture, as the base resin, by virtue of its chemical nature, it determines the properties of the cured surface layer.
  • the monoacrylate to hexaacrylate or monomethacrylate to hexamethacrylate added makes it possible as a diluent monomer or oligomer, to adjust the viscosity of the mixture to be cured, which is normally within a viscosity range from 20 to 100 poise at 20° C, and entirely takes part in the free radical polymerization.
  • the coating is cured through free radical polymerization between the double bonds of the prepolymer and of the diluent monomer or oligomer which may be present.
  • Fig. 1 illustrates an embodiment of a method of manufacturing a panel for covering a floor, a wall, a ceiling or furniture by means of covering a substrate 1 according to the invention.
  • the substrate 1 is placed on a conveyor belt 2 and moved from the left to the right as indicated by arrows in Fig. 1 .
  • the substrate may be MDF, HDF, particleboard, multi-layer wood, cellulose-based materials such as paper or cardboard, metals, plastic material (PVC, polyester, polyolefins), stone, glass, ceramic and compounds thereof, but numerous alternative materials are conceivable.
  • the substrate 1 is conveyed to a first digital printing station 4', preferably comprising an inkjet printer, for printing a decorative pattern directly on top of the substrate 1.
  • a layer of curable substance 3 is applied on top of the substrate 1, in particular on top of the decorative pattern.
  • the curable substance 3 comprises a resin in the form of a pasty liquid which cures through polymerization when irradiated by UV radiation.
  • the substrate 1 and the layer of curable substance 3 pass a second digital printing station 4, e.g. an inkjet printer, which prints a pattern of discrete quantities of an additional substance 5, for example in the form of solid additional substance 5 or pasty substance, on top of the layer of curable substance 3, hence at a side of the layer of curable substance 3 which is directed away from the substrate 1.
  • a second digital printing station 4 e.g. an inkjet printer, which prints a pattern of discrete quantities of an additional substance 5, for example in the form of solid additional substance 5 or pasty substance, on top of the layer of curable substance 3, hence at a side of the layer of curable substance 3 which is directed away from the substrate 1.
  • the layer of curable substance 3 is still uncured or only partly cured. This means that the additional substance 5 may partly penetrate into the layer of curable substance 3, depending on the material characteristics of the layer of curable substance 3 and the additional substance 5 and on velocity of the additional substance 5 when arriving on the layer of curable substance 3.
  • the discrete quantities of the additional substance 5 are printed according to a pattern that is in register with the decorative pattern printed in the first digital printing station 4'.
  • a substantially air-tight foil 6 is applied on top of the layer of curable substance 3 such that it contacts both the additional substance 5 and an upper surface of the layer of curable substance 3 around the additional substance 5.
  • the foil 6 is adapted such that it allows transmission of UV radiation.
  • Fig. 1 shows that the layer of curable substance 3 including the additional substance 5 are sandwiched between the substrate 1 and the foil 6.
  • the foil 6 is pressed at a low pressure level on the layer of curable substance 3 by means of a calander 7.
  • the layer of curable substance 3 including the additional substance 5 and the foil 6 pass a UV radiator 8 which irradiates the layer of curable substance 3 through the foil 6. Consequently, the layer of curable substance 3 is cured into a layer of cured substance 3'.
  • Fig. 1 further illustrates that after the step of curing at the UV radiator 8, the foil 6 is removed from the layer of cured substance 3'.
  • a lower surface of the foil 6 that is directed to the layer of cured substance 3' is sticky such that attractive force between the additional substance 5 and the foil 6 is greater than between the additional substance 5 and the layer of cured substance 3'. Consequently, the additional substance 5 are removed from the layer of cured substance 3' together with the foil 6.
  • An upper surface of the layer of cured substance 3' of the resulting product has a three-dimensional structure in the form of the pattern of additional substance 5 that were applied on top of the layer of curable substance 3 in a previous step.
  • the layer of cured substance 3' is fully cured at the UV radiator 8, which may be achieved by using relatively small particles or particles which allow transmission of UV radiation. It is also conceivable that the upper surface of the layer of curable substance 3 is not fully cured at portions directly below the particles. These portions may be cured in an additional radiation curing step.
  • the resulting panel may be cut in separate boards of which edges may be provided with locking means, for example tongues and grooves, in order to create a covering by locking similar boards to each other.
  • locking means for example tongues and grooves
  • Fig. 2 illustrates an alternative embodiment of the method according to the invention. Elements which correspond to elements in Fig. 1 and which have the same function have the same reference numbers.
  • the substrate 1 is also placed on the conveyor belt 2 and moved from the left to the right as indicated by arrows in Fig. 2 .
  • the air-tight foil 6 is applied onto the layer of curable substance 3 before a pattern of additional substance 5 is printed onto the foil 6 at the printing station 4.
  • the additional substance 5 are adapted such that they allow less transmission of the radiation than the foil 6.
  • the substrate 1, the layer of curable substance 3 and the foil 6 including the additional substance 5 pass the UV radiator which irradiates the layer of curable substance 3 through the foil 6. Consequently, the layer of curable substance 3 is partly cured into a layer of partly cured substance 3". Since the radiation cannot or can only partly pass through the additional substance 5 the layer of curable substance 3 remains uncured at shallow upper portions 9 thereof which are located directly below the respective additional substance 5. The uncured upper portions 9 are exposed after removing the foil 6 including the additional substance 5 from the layer of partly cured substance 3", as illustrated in Fig. 2 .
  • substrate 1 and the layer of partly cured substance 3" are moved to an excimer lamp station 10 where a step of additional radiation curing is performed.
  • the UV radiation of the excimer lamp station 10 has a limited penetration depth in the layer of partly cured substance 10, but the penetration depth is sufficient to cure the shallow uncured upper portions 9. This results in cured upper portions 9' within the layer of cured substance 3'.
  • the upper surface of the upper portions 9' and their surrounding upper surface of the layer of cured substance 3' have a different texture, which reveals in different gloss level.
  • the discrete quantities of an additional substance may be droplets of a liquid or a pasty substance, which may be solidified afterwards, for example via curing, preferably together with curing the curable substance.
  • the invention is further disclosed by the following item list as defined by the below numbered items.

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  • Application Of Or Painting With Fluid Materials (AREA)
EP21188714.6A 2021-07-30 2021-07-30 Un procédé de fabrication d'un panneau Pending EP4124467A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP21188714.6A EP4124467A1 (fr) 2021-07-30 2021-07-30 Un procédé de fabrication d'un panneau

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP21188714.6A EP4124467A1 (fr) 2021-07-30 2021-07-30 Un procédé de fabrication d'un panneau

Publications (1)

Publication Number Publication Date
EP4124467A1 true EP4124467A1 (fr) 2023-02-01

Family

ID=77431100

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21188714.6A Pending EP4124467A1 (fr) 2021-07-30 2021-07-30 Un procédé de fabrication d'un panneau

Country Status (1)

Country Link
EP (1) EP4124467A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2927017A1 (fr) 2014-04-04 2015-10-07 Spanolux N.V. Div. Balterio Procédé de recouvrement d'un substrat
US20160114619A1 (en) * 2008-12-19 2016-04-28 Flooring Industries Limited, Sarl Methods for manufacturing panels and panel obtained thereby
EP3403847A1 (fr) * 2017-05-17 2018-11-21 Surteco Decor GmbH Procédé de fabrication d'une bande de matériau multicouches comprenant une surface structurée par embossage par repérage et son utilisation
WO2020115337A1 (fr) * 2018-12-03 2020-06-11 Barberan Latorre Jesus Francisco Procédé et dispositif pour obtenir un relief sur un substrat
EP3892388A1 (fr) * 2020-04-06 2021-10-13 Fritz Egger GmbH & Co. OG Procédé et dispositif de fabrication d'une surface structurée d'une matière en forme de plaque

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160114619A1 (en) * 2008-12-19 2016-04-28 Flooring Industries Limited, Sarl Methods for manufacturing panels and panel obtained thereby
EP2927017A1 (fr) 2014-04-04 2015-10-07 Spanolux N.V. Div. Balterio Procédé de recouvrement d'un substrat
EP3403847A1 (fr) * 2017-05-17 2018-11-21 Surteco Decor GmbH Procédé de fabrication d'une bande de matériau multicouches comprenant une surface structurée par embossage par repérage et son utilisation
WO2020115337A1 (fr) * 2018-12-03 2020-06-11 Barberan Latorre Jesus Francisco Procédé et dispositif pour obtenir un relief sur un substrat
EP3892388A1 (fr) * 2020-04-06 2021-10-13 Fritz Egger GmbH & Co. OG Procédé et dispositif de fabrication d'une surface structurée d'une matière en forme de plaque

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Owner name: UNILIN, BV