Patent ID: 12251960

DESCRIPTION OF NON-LIMITING EMBODIMENTS

FIG.1schematically represents some steps S1-S5in a method for manufacturing coated panels1. The respective coated panels1are of the type comprising at least a substrate2, for example, a MDF or HDF basic panel, and a top layer3provided on this substrate2. In the example, the top layer3is composed of a plurality of material layers4-7, amongst which a material layer5, which shows a motif and which, during step S2, is provided in the form of a print8performed directly on the substrate2.

In a previous step S1, one or more priming layers4are provided on the surface of the substrate2to be printed with the motif. These 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 layers5-8to be applied later, such as for the material layer5with the motif, or for the synthetic material layer7. As mentioned in the introduction, all these functions possibly may be fulfilled by a material layer which comprises polyvinyl chloride and/or plasticizer.

FIG.2represents the result of step S1and shows that a possibly uneven surface of the substrate2can be made flat or approximately flat by means of said one or more priming layers4.

In the example, in step S1use is made of an application technique by means of one or more cylinders9. It is clear that in step S1ofFIG.1, also other application techniques may be applied for realizing one or more priming layers4. At the same time, it is clear that it is not necessary for the invention that such priming layers4are applied, although this may be important for the quality of the motif. Instead of working with a priming layer4which is applied in liquid form, use may also be made of a priming layer4comprising a material sheet, such as a paper sheet, and which is provided on the substrate2in dry or quasi-dry form. In the case of a polyvinyl chloride paste, this paste preferably is at least partially gelled while already having been provided on the substrate.

As aforementioned, in step S2ofFIG.1a motif is realized by means of a print8which is performed directly on the substrate2or, in this case, on a priming layer4already provided on the substrate2. The obtained motif relates to a wood motif extending over the entire length of the oblong rectangular panel1. Of course, the invention is not restricted to such motifs. Preferably, such print is performed by means of UV inks.

In this case, for providing the printed motif use is made of an inkjet printer10with 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 panel1can be covered by means of a multi-color print. According to another example, use can be made of a so-called multi-pass inkjet printer, wherein the inkjet print heads move to and fro over the substrate. It is evident that the present invention for step S2neither is restricted to inkjet printing techniques, nor to motifs printed directly on the substrate2.

FIG.3represents the result of the print8performed indirectly on the substrate2, in this case on a priming layer4already situated on the substrate2. As noted above, the print8results in the material layer5, which shows the motif.

In step S3ofFIG.1, an additional print6is provided above the printed motif. This relates to a print6with an expansion-preventing agent. The print6is performed with a pattern which will determine the final structure of the relief of the coated panel1. 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 panel1. In this case, the pattern forms a mask which provides the edges11of the panel1as well as certain locations12in the surface of the panel1with such expansion-preventing agent. Herein, the locations12in the surface of the panel1correspond to wood flowers or wood nerves present in the wood motif and will lead to recesses present in the panel1, which imitate wood pores.

FIG.4once again clearly shows the locations11-12of the print6provided in step S3.

In step S3, it is represented that the print6, which determines the relief or the structure, is provided by means of a digital printing technique, such as by means of an inkjet printer10. It is clear that it is not excluded that the print6or the expansion-preventing agent can be applied in another manner.

In step S4ofFIG.1, a synthetic material layer7is applied. Such synthetic material layer7preferably consists of a transparent or translucent matter and preferably extends over the entire panel1concerned. In this case, use is made of a foamable synthetic material, more particularly polyvinyl chloride with plasticizer. In the example, a cylinder9is shown for applying such layer. However, it is clear that this synthetic material layer7can be provided in any manner. It is also possible that in step S4a plurality of synthetic material layers7situated 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 layer7. For example, they may be blended or woven into the synthetic material or into the synthetic material layer7beforehand or can be strewn into the already provided synthetic material layer7or deposited in another manner.

FIG.5shows the result obtained after step S4.

In step S5ofFIG.1, a relief is provided at the surface of the synthetic material layer7applied in step S4.

FIG.6represents that herein, a coated panel1is obtained which shows a pattern of recesses13and projections14at its surface, wherein this pattern is at least partially determined by means of the print6with expansion-preventing agent applied in step S3. This structure is obtained in that the synthetic material layer7is activated in step S5and starts to expand, or in other words will foam or gel. This activation may be obtained, for example, by heating the synthetic material layer7by means of a hot-air oven15or an infrared oven.

FIG.6shows that at the places where in step S3expansion-preventing or expansion-reducing agent is applied, said expansion has occurred to a lesser extent or not at all. At those places, there are recesses13in the surface of the thickened synthetic material layer7. In this way, in the example chamfers16have been obtained at the edges11of the coated panel1, and recesses13have been obtained in the surface of the panel1for imitating wood pores17. It is evident that the technique of the invention may also be applied for obtaining chamfers16only or obtaining imitations of wood pores17only or for obtaining other structures.

FIG.6also shows that the obtained recesses13may have a structure with strong rounded portions18.

FIG.7shows a possibility for obtaining sharper structures. Herein, when expanding the synthetic material layer7, in step S5a forming mold19can be applied, against which the expanding synthetic material layer7is rising. Such technique may be interesting for forming sharper chamfers16. In the represented example, the forming mold19is a substantially flat press element. However, it may also be worked with one or more press cylinders or molding wheels.

It is clear that herein, an embodiment is obtained wherein the first and second possibility for forming structure or relief at the surface of the coated panels, mentioned in the introduction, are combined.

FIG.8represents another possibility for obtaining sharper structures, such as sharp chamfers16. Herein, the aforementioned one or more prints6, which determine the structure, are performed with a so-called degrade, wherein the intensity or the amount of applied agent of the print6is 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 inFIG.7.

Applying such degrade also has advantages in all aspects where the relief is at least partially determined by means of a preferably digital print.

It is clear that the method ofFIGS.1to6and the variants ofFIGS.7and8form examples of said first and second aspect, as well as that the obtained coated panels form examples of said first aspect.

It is clear that the results of the methods according to the invention depicted inFIGS.6and7can be finished even further with one or more finishing layers, such as lacquer layers and the like.

It is noted that the thickness of the material layers and substrates represented inFIGS.2to7is 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 15 millimeters, or thicker.

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.