CN104684737B - The digital embossed surface being mutually aligned - Google Patents
The digital embossed surface being mutually aligned Download PDFInfo
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- CN104684737B CN104684737B CN201380038014.6A CN201380038014A CN104684737B CN 104684737 B CN104684737 B CN 104684737B CN 201380038014 A CN201380038014 A CN 201380038014A CN 104684737 B CN104684737 B CN 104684737B
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Abstract
The present invention relates to building panelling especially floor panel and using digital ink-jet capitiform into the method for the embossed surface being mutually aligned.By curable ink, on the upper side of panel surface or paillon and ink matrix is formed, which is used by applying pressure in ink matrix to form cavity on said surface the digital ink-jet head for sprayed coating in the form of coating.
Description
Technical field
This patent disclosure relates generally to the panelling fields with decorative wearing face, especially floor and wallboard.The present invention relates to
And with such decorative surface building panelling and manufacture as panelling manufacturing method.
Application field
Multiple embodiments of the present invention are especially suitable for utilization in can be by floor that such floor panel is formed, the floor
Panelling includes core plate, decorative layer and the transparent wearproof structural tier above decorative layer.Therefore, below on known system
Technology, the purpose and feature of multiple embodiments of problem and the present invention description will be used as not limiting example mainly for
This application field is simultaneously illustrated especially for similar to traditional laminate flooring or the floor with resilient surface layer.
It is emphasized that multiple embodiments of the present invention can be used in any kind of panelling for example in such as wall
Superficial layer is manufactured in the building panelling of plate, ceiling and furniture parts and analog.This method can be used in wood floors, second
Alkenyl floor forms patterned structure as being referred to as in LVT floors and ceramic tile.
Background technology
Most of laminate flooring is manufactured according to the manufacturing method for being commonly known as direct pressing laminating (DPL).
Such laminate flooring includes 6-12 millimeters of fiber plate core, the upper decorative surface layer of 0.2 millimeters thick of laminar structure and lamination
Lower balance layer, plastics, paper or the similar material of the 0.1-0.2 millimeters thicks of structure.
The superficial layer of laminate flooring is characterized in that decorative and wearability is usually obtained using two stacked independent paper layers
.Decorative layer is typically printing paper and wearing layer is the transparent mulch paper for including little particle aluminium oxide.
The facing paper and mulch paper of printing are through melamine resin impregnation and the tegillum in large laminator
It is pressed onto high-density fiber (HDF) core plate.Wherein, in the large laminator, resin is solid under high temperature (160-220 DEG C) and high pressure
Change and paper is in turn laminated to core material.The pressing plate of embossing forms surface texture.Sometimes, the paper of structuring is used as extrusion pressing type
Piece.
Printing technology manufacture can also be used in laminate flooring.One advantage is can to avoid extrusion operation and without printing paper
To provide decorative wearing face.
Floor panel with the laminating surface directly printed includes the high-density fiber (HDF) identical with DPL types
Core plate.Decoration is directly printed onto on core plate.The manufacturing method is considerably complicated and only in very big production-scale feelings
It is just cost-effective under condition.
Water-based printing ink is used by the multicolour printing with the roller being directly printed onto on pre-sealed core plate
Machine carrys out printed decoration.Printed decorative layer must be protected in order to avoid wearing.Realizing the most common method of high abrasion resistance strength is
Using anti abrasive ultraviolet light fluid sealant, it is applied on stamp by roller and is cured under action of ultraviolet radiation.Patterned structure
It can be formed by knurling rolls.
The technology of directly printing can be by digital printing technical substitution, and the digital printing technology is more flexible and can be in small production
It is economically fabricated under scale.The difference of both approaches is mainly print steps, and in the print steps, print roller is non-by number
Contact printing process substitutes, and wherein desired image is directly applied on pre-completed core plate.Protect digital picture most
Whole clear coat and body structure surface be typically with directly print in type used it is identical.Any type or print can be created
Map brushing picture, but surface texture is confined to the form of the knurling rolls or structural membrane to press to surface always.
Digital printing may be alternatively used for being printed onto on the scraps of paper used in traditional laminate product.Stamp can be applied to list
On paper solely impregnate or untreated, which is laid on core plate after printing.Unprocessed paper can also be laid into and include
On the core plate of resin, the resin is infiltrated through in extrusion process in the unprocessed paper.Major advantage is to avoid impregnating
With point-device positioning of paper.
Have been developed for new " no paper " floor type recently, wherein the surface of solids is included by fiber, binding agent and wear-resisting
The substantially uniform mixture of powders of particle composition.
The mixture of powders can include alumina particle, melamine resin and wood-fibred.In most applications,
Include decorative particles such as pigment in the mixture.In general, all these materials are with dry mix powder shape
Formula is applied on HDF core plates and is cured into 0.1-1.0 millimeters of solid layer under heat and pressure.Melamino-formaldehyde
Resin and wood-fibred can be substituted by thermoplastic granulates.
It can obtain compared to known technology and especially compared to multiple advantages of traditional laminate flooring, such as enhancing
Wearability and impact resistance, the deep production chains for being embossed, enhancing and relatively low cost.
Powder technology is highly suitable for manufacturing decorative surface layer, this layer is the copy of stone and ceramics.But it is more difficult to
Form the such design of such as wooden decorative.But nearest digital powder printing has been developed and can be by imprinting
It is preceding to inject digit printing in powder to form any kind of very advanced design.Surface texture is with identical with laminate flooring
Mode be made up of the structure laminate that being pressed onto on powder or embossing matrix paper.
Floor with wood grain surfaces manufactures in a number of different manners.Traditional solid wood grain floor has been developed as
With the engineering floor for being laid into the layer of wood made of wooden thin plate, HDF or the glued board on core plate.It is most of such
Floor is all as the preform floor transport with such wood grain surfaces, and wherein the wood grain surfaces are coated in the factory
Multi-layer transparent layer.Recently, timber floor has also been manufactured into digital printing pattern, which, which improves, does not have
The design of wood grain structure in the timber variety of enough surface quality.
Most of above-mentioned floors all have the surface texture of embossing, especially when decorative printed decoration is wood grain figure
During case.The patterned structure was provided in the past with being used for the individual overall structure type of many different decorated types.Recently,
Most of floor suppliers, which have been incorporated into, is mutually aligned/accurate overlapping embossing (EIR) method, and wherein embossed surface structure is to be directed to
Each type of timber variety is specifically created and embossing is manufactured in a manner of being mutually aligned with printed decoration.This, which is provided, changes
Into design, which is difficult to be distinguished with nature material such as timber and stone material.Embossed surface is surface texture and the base of design
This part and if such structure can by more flexibly and low cost in a manner of be formed if it will be favourable.
The definition of some terms
Hereinafter, the visible surface of mounted floor panel is referred to as " front ", and floor panel is downwards
The opposite side on floor is referred to as at " back side "." superficial layer " refers to such all layers, is that panelling provides its decoration performance and its
Wear-resisting property and all layers being applied on entire positive core plate that is positive, preferably covering floor.
" stamp " refers to decorate, design, pattern or image." upward " refers to refer to towards the back of the body towards front and " downward "
Face." vertically " refer to " flatly " refer to parallel to the surface perpendicular to the surface.
" pigment for being used for digital printing ink " refers to change reflected light or transmitted light due to the selective absorbing of wavelength
Color material.
" dye ink " refers to coloring matter, has affinity to the substrate that will be applied to that.Dyestuff is usually can also wrap
The form of aqueous solution containing adhesive applies, and can need mordant to improve fastness of the dyestuff on fiber.With cannot
The little particle pigment of dissolving is compared, and dyestuff is completely soluble as sugar.
" aqueous or water-based inks " refer to such a ink, and wherein water is used as the liquid in ink.It is water base
Liquid carries pigment.Also there are adhesives so that pigment is bound to substrate in system.
" solvent-based ink " refers to such a ink, usually contain three kinds of major parts such as fluid carrier, pigment and
Resin.Technically, solvent-based ink usually refers only to the oil based vehicle part of ink, which is maintained at liquid by other parts
Form and pass through injection evaporation disposably applied to surface.
" ink or coating of ultraviolet-curing " refers to such ink or coating, after the application in ultraviolet furnace
Got off curing by being exposed to intensive ultraviolet.
" matrix (matrix) " refers to such material, i.e., forms embossed surface knot when this material is pressed towards surface
Structure.
" non-gloss ink " refers to a kind of curable ink or coating material, works as and is laid, cured and be pressed onto in substrate
When recessed portion is formed in substrate." ink matrix " refers to the extruding matrix formed by non-gloss ink substance, and wherein this is without gloss oil
Ink is cured into hard structure, so that it can form recessed portion on the surface in extrusion process." digital coating " refers to
Pass through the digital sprayed coating of the curable ink of digital ink-jet head.
" being mutually aligned embossing " or EIR refer to that stamp decoration is mutually aligned with boss structure." number being mutually aligned is variable
Embossing " (DVEIR) refers to be mutually aligned embossing by partially or even wholly digital formation and accurately match somebody with somebody with the variation of stamp decoration
Change accurately.
Known technology and they there are the problem of
The common technique for being used to provide digital printing industrially applied is described below.Multiple methods described below can
It is used singly or in combination the digital printing or digital application of the substance in multiple embodiments to form the present invention.
High-definition digital printer uses nonimpact printing technique.The printing machine has print head, the print head
In very accurate way by ink droplet from print head " injection " to substrate.
Multi-way printing (scanning is also made to print) is a kind of such printing process, and wherein print head laterally moves above substrate
It moves repeatedly to generate image.Such press speed is slow, but a small print head can generate larger image.
Industrial printing machine is normally based on print pass method, and this method uses fixed print head, the print head
Width is corresponding with the width of printed medium.Printed substrate moves below print head.Such printing machine has height
Production capacity and they be equipped with multiple fixed print heads of the alignment that follows one another along feeding direction.Each print head printing
A kind of color.Such printing machine can be directed to each applied customization.
Fig. 1 a show single pass printer 35, and including 5 digital print head 30a-e, they are connected to using black pipe 32
Ink reservoir 31 filled with different colours ink.These ink guns are using digital data line 33 or are wirelessly connected to digital control
Unit 34, the number control unit 34 control ink droplet application and conveyer belt 21 speed, the conveyer belt by panelling accurately
It is transplanted below print head, to ensure the high quality image for including multiple color.
The normal width of industrial print head is about 6 centimetres and can print out arbitrary length.1-2 meters of large area region can
It is printed using the digital printer of multiple rows of print head including side-by-side registration.
Dots per inch or DPI are used for the resolution ratio for defining digital printer and press quality.300DPI is usually for example
It is to be enough to print the wood grain structure for applying the same quality in traditional laminating wooden floor at present.Industrial printing machine can be more than 60
M/min speed printing have 300-1000DPI resolution ratio and even more high-resolution pattern.
The printing can be " full version printing ".This means visual printed decoration mainly by be applied to powder or
Ink pixel on superficial layer is formed.In such embodiment, the color or primary colours of powder bed are to visible pattern or decoration
Usually there is limited influence.
The printing can also be " local printing ".The color of another base is the visible one of which in final decoration
Color.Compared with full version printed design, it is attributed to reduction ink and uses and increase printing capability, the face of printed pixel covering
Product and the amount of the ink used can reduce simultaneously escapable cost.
Printing can be based on printing four color separations (CMYK) color principle printing.This be it is a kind of comprising cyan, magenta, yellow and
The 4- colors of black are set.They, which are mixed, to provide relatively small color space/colour gamut.In order to increase particular color or
Entire colour gamut can increase color a little.The color of point can be any color.Multiple color is mixed and passes through software and hardware
The combination of (print engine/print head) controls.
Innovation AB have been developed for new technology, which can spray digit printing to powder
In layer.The fact that stamp is made into the powder being cured after printing is attributed to, obtains this new " digital code spray-jet print
Flower " or DIP.Stamp is embedded into cured layer rather than is applied to as when using traditional printing methods on layer.
Stamp can be horizontally and vertically in place by sizes with different depth.This can when using vitreous fibre
Three-dimensional (3D) effect is used to form to enhance wearability.The protective layer of original design need not be disturbed.
DIP methods can be used in it is all can be after printing in cured powder-based material.But DIP methods are especially in powder
It is particularly suitable during mixture comprising wood-fibred, hard, wear-resistant little particle and melamine resin.Superficial layer can also include
Thermoplastic material, such as vinyl particle, are applied in substrate in powder form.This allows stamp that can be injected into ethylene
In base powder particles.Even if in such material, also improved design and improved wearability.
Have to using suitable print head obtain high press quality in powder base and other layers as described above
And speed.Print head have multiple small nozzles, they can eject in a controlled manner droplet of ink (drop on demand ink jet technology-
DOD).The size of each drop can change according to ink type and printhead type between 1-100 picoliters.Can design can
Eject the print head of up to 200 picoliters of bigger drop.Some print heads it is sprayable go out different drop sizes and they
Gray scale can be printed.Other print heads only it is sprayable go out a kind of fixed drop size.
A variety of different technologies can be used for drop spraying delivery nozzle.
Thermal print head technology use with it is a series of comprising heater microlaser cavities printing box, each of which by
The photolithograph art of printing is configured to.In order to spray drop from each chamber, a current impulse causes ink by heating element
In intracavitary fast vaporizing to form bubble, the formation of bubble causes pressure to greatly increase, so as to promote ink droplet through nozzle project to
Substrate.It is printed from the most users ink jet type printing printing machine including Canon, Hewlett-Packard and company of Lexmark of the U.S. using temperature-sensitive
Head.
Most of commercial and industrial ink jet type print heads and certain user's printing machine are as by Seiko Epson Corporation's production
Printing machine uses piezoelectricity/piezoelectric print head technology.The piezoelectric material in ink filled cavity behind each nozzle be used to replace
It is used for heating element.Upon application of a voltage, piezoelectric material changes shape, this generates force in drops out from nozzles in a fluid
The pressure pulse of ejection.Piezoelectricity (also referred to as piezoelectric type) ink-jet printer allows the broader ink type of specific heat ink-jet printer,
Because it is without volatile component, and there is no the problem of coking.The ink such as dye ink, solvent base of many types can be used
The ink of ink, latex ink or ultraviolet-curing.
Ink is usually uniquely mixed by using pigment and multi-chemical.Water-based inks comprising pigment
High-quality printing process be especially suitable for and that low cost can be provided in a variety of different materials.
The above-mentioned description for various known arrangements is only the description of applicant, and it is existing to be not an admission that any of the above described description
There is technology.Above-mentioned multiple technologies are known and are alone applied rather than all combinations as described above and method.
Fig. 1 b-1c show the formation of embossed surface.Wood grain structure WG is provided to as stamp P on surface 2, such as Fig. 1 b
Shown in.The surface is pressed in matrix, which usually has the steel plate of embossing, and the coin segment of basis of formation embossing
17 are formed in recess or convex form in surface 2, as illustrated in figure 1 c.Fig. 1 d show the formation on EIR surfaces.Coin segment 17
It is mutually aligned/accurate is built up and coin segment 17 is located in the top of stamp part P with stamp P.
Fig. 2 a-c are shown forms EIR surfaces on laminate flooring.The usually combination of steel plate or steel plate and embossing paper layer
Matrix 40 be pressed onto by pressing plate 24 in printed surface 2 and EIR surfaces 16 are formed after compacting as shown in Figure 2 c.
EIR provides very advanced design, is difficult to be distinguished with real wood.But the technology is costly and complicated,
Because the decorative paper or stamp on panel must be formed relative to the embossed steel plates charta tabella of patterned structure or roller essence
Determine position.
One of major defect of known technology is can not to avoid repeating effect.Size is made in most of laminate floorings
The big sheet material of 2.1 × 2.7m and when floor panel passes through the locking system to be formed as shown in Fig. 2 d that cuts and mill
When, this provides about 10 panellings or 5m2Floor area.Printing roller usually has the perimeter of 1.3m and this means the pieces
Material is made of two identical piece portion S1 and S2.
If using digital printing, limitation is not present to the size of decoration.But the repeating effect of structure matrix can not be kept away
Exempt from.Fig. 2 e show that digital printing allows 10 independent panellings that can not repeat to manufacture, but always have some with phase in floor
With the floor panel of surface texture.Some manufacturers are using dual stamp and can use two block pressur plates.This be it is a kind of it is expensive simultaneously
Complicated manufacturing method and floor area is still limited to about 10m2, installation can be maximized without caused by body structure surface
Repeating effect.
In short, it may be mentioned that digital printing is very flexible method, but its can not possibly fully with EIR surfaces
It is used in combination, because printing ornament must be always adapted to the pressing plate, roller or film of embossing.The common spy on above-mentioned all these floors
Sign is that all surface has identical foundation structure and can not be adapted and adjusted to any variation of decoration.It is this to repeat to imitate
Fruit provides a kind of floor surface, dissimilar with wood floors, in wood floors, due to the wood grain structure of timber cause it is several
All panellings are respectively provided with different design and structure.The duplicate of stone and other natural materials can not possibly be in this way
It is produced, i.e., it is the accurate duplicate of natural material, wherein design and structure are usually by perfect adaptation and all panellings
It is different.
Even when using being decorated by Conventional decal made of printing roller, body structure surface is also expensive, because with
Very high in the cost of embossed steel plates/roller and described steel plate is when they are squeezed using high pressure towards the surface comprising abrasion resistant particles
It is subject to sizable abrasion.If embossed surface and especially EIR surfaces can will be in this way most by manufacture
The advantages of main, i.e., such mode cost is lower and allows patterned structure phase in a manner of with digital printing decoration being allowed to change
Same mode changes.
It is related that digital application technology is mainly used only for the possibility for obtaining in a flexible way to forming high-definition picture
The advantages of.But relate generally to extremely accurate lay the other aspects of the technology of the possibility of substance by the way of non-compression
It is not also fully utilized or develops, combined typically without with the substance for being not intended to be formed image.
EP 2 108 524 describes a kind of method, wherein with two or more digit printings stacked on top of each other
Protrusion is formed in substrate.
US 2013/0043211 describes a kind of method, including curable materials or surface are removed substance with predetermined
Pattern be printed onto on panelling, at the pattern of panelling formed height or removal panelling a part of surface.Stamp can be with
It is digit printing and surface removal substance can be liquid mixed with powder.Substance is selected so that itself and panel surface are reacted,
So as to which its a part be removed.
The method is unsuitable for applying in laminar structure and powder comprising thermosetting resin cured under heat and pressure
In last base plate.They are unsuitable for forming patterned structure in other surfaces, and other surfaces are, for example, by being protected on squeezing
Protect wood grain and the vinyl surface that superficial layer is formed.
EP 2 213 476 describes a kind of method, whereby, predetermined pattern is printed on load using curable liquid
On body, so as to form embossing.The major defect of this method is that curable liquid is applied in extrusion process and base
On the lower surface of the carrier of bottom contact.Curable liquid must be glued fast on carrier, so as to the quilt when removing carrier
It removes.This is complicated operation, because it is it is difficult to be bonded to load in a secure fashion that carrier, which generally comprises releasing agent and liquid,
Body.Identical carrier can not possibly be used for different embossed patterns.
If patterned structure can utilize be applied to the pressure on surface in a flexible way especially it is digital formed if will
The advantages of being main.
The content of the invention
The purpose of certain embodiments of the present invention is to provide a kind of building panelling, especially a kind of floor panel, Yi Jiyi
The method that kind has this kind of building panelling of embossed surface for manufacture, wherein, embossed surface can be more flexible and more economical
Mode manufacture and adapt in the fabrication process can be digit printing printed decoration.
Above-mentioned purpose is exemplary, and multiple embodiments of the present invention can realize different or additional embodiment.
One embodiment of the present of invention is based on a main principle, wherein variable embossing passes through the curable of digital application
Ink (also referred to as non-gloss ink) is formed, which forms matrix (referred to hereinafter as ink type after number applies and cures
Piece), compared with substrate squeeze the ink matrix and substrate cure and from substrate move up except ink matrix after in substrate
Form patterned structure.This allows flexible embossing to be formed through pressing steps, and such embossing can be with flexible digit printing phase
Cooperation, wherein each panelling can different decorations and structure with no repeating effect.
The first scheme of the present invention is a kind of method that embossed surface is formed in building panelling.This method includes following step
Suddenly：
It is formed by using the curable ink of digital ink-jet head sprayed coating with horizontal-extending size and vertical extension
The ink matrix of size；
Ink matrix is located on the superficial layer of building panelling；
Cavity is formed on the superficial layer by squeezing the ink matrix compared with superficial layer, so as to form the building
The embossed surface of panelling；With
The ink matrix is removed from the embossed surface.
One embodiment of first scheme according to the present invention provides a kind of formation embossed surface in building panelling
Method.This method comprises the following steps：
To have by using digital ink-jet head in curable ink sprayed coating to the superficial layer of building panelling to be formed
The ink matrix of horizontal-extending size and vertical extension size；
Cavity is formed on the superficial layer by squeezing the ink matrix compared with the superficial layer, is built so as to form this
Build the embossed surface of panelling；With
The ink matrix is removed from the embossed surface.
The building panelling can be floor panel.
The superficial layer may include the decorative layer that there is stamp to be preferably digit printing.
The cavity can be formed in which be mutually aligned with the stamp.
The digital ink-jet head can be piezoelectric type nozzle.
The curable ink can be polymer material, be preferably the polymer material of ultraviolet curing.
This method, which may also include, cures the step of curable ink is to form ink matrix.
The ink matrix can be formed on the superficial layer of the building panelling.
The ink matrix may be formed in substrate, be preferably formed in the basic type on piece being forced into panel surface.
This method can be used for forming patterned structure on panelling, which includes the basis formed by classical production process
Embossing and the complementary embossing for being specially matched with each panelling and number formation.
The alternative plan of the present invention is one group of building panelling, and the building panelling has superficial layer, and the superficial layer includes
Decorative layer and the upper strata of embossing processing.The decorative layer includes variable stamp and the upper strata of the embossing processing is included for the group
The essentially identical basis of building panelling embosses and for the differentiable variable embossing of each building panelling.The variable embossing is with being somebody's turn to do
Variable stamp is mutually aligned.
The variable embossing of each building panelling can be unique or unique.
The building panelling can be floor panel.
The variable stamp can be digit printing.
The basis embossing can be formed in which be mutually aligned with the basic engineering of decorative layer.
The basic engineering of the decorative layer can be stamp, be preferably digit printing.
The building panelling can be configured with embossed surface, which allows installation to be greater than about 10m2, preferably greater than
About 15m2Floor area, wherein all panellings are respectively provided with different surface textures.For example, can produce respectively has different tables
The different building panellings for being more than 20 of face structure.
This basic principle can also be used to for patterned structure to be applied to the paillon contacted with pressing plate in extrusion process
Upper surface on.The patterned structure is pressed into paillon in extrusion process and the paillon automatically forms to be formed in panel surface
The extruding matrix of recessed portion, wherein the curable ink or non-gloss ink of digital sprayed coating form ink matrix.Advantage is the paper tinsel
Piece is easily removed from by pressure surface and the surface texture of paillon can be used for even in the surface element formed by ink matrix
The upper part basis that formed is divided to emboss.
The third program of the present invention is a kind of method for the matrix for forming to be formed embossed surface on building panelling, is wrapped
Include following steps：
- matrix is provided, which includes the paillon with lower part, which is included in extrusion process and building panelling
Surface contacts and the matrix is prevented to be adhered to the release surface on the surface of building panelling, and the surface of the building panelling is preferably built
Build the thermosetting surface or thermoplastic surface of panelling；With
- using digital ink-jet head by curable ink sprayed coating to the paillon and the surface of building panelling it is discontiguous on
Portion, so as to form ink matrix on the paillon.
The curable ink can be polymer material, preferably the polymer material of ultraviolet curing.
The step of this method, which further includes, cures ink matrix, and preferred consolidation is into hardness of matter.
The fourth program of the present invention is for forming embossing on the building panelling manufactured according to the third aspect of the invention we
The matrix on surface.
The 5th scheme of the present invention is the method that embossed surface is formed on building panelling, is comprised the following steps：
- offer paillon；
- form curable ink sprayed coating with horizontal-extending to the top of the paillon by using digital ink-jet head
The ink matrix of size and vertical extension size；
- paillon is squeezed by the superficial layer compared with building panelling lower part and the ink matrix positioned at the paillon top
Cavity is formed on the superficial layer of building panelling, so as to forming the embossed surface of the building panelling；With
- remove the paillon and the ink matrix from the embossed surface.
The building panelling can be floor panel.
The superficial layer may include the decorative layer that there is stamp to be preferably digit printing.
The cavity can be mutually aligned with the stamp.
The digital ink-jet head can be piezoelectric type nozzle.
The curable ink can be polymer material, preferably the polymer material of ultraviolet curing.
This method, which may also include, hardens the ink matrix, preferably hardens into hardness of matter.
The paillon can be metal foil, preferably aluminium foil or plastic film.
The superficial layer of the building panelling can include thermosetting resin, be preferably melamine resin.
The present invention the 6th scheme be for forming the basic matrix of embossing on the surface of building panelling, wherein, the base
Plinth matrix is aluminium foil or plastic film or coated paper, which includes：
For the lower part for being extruded and being discharged from the surface of the building panelling；
The non-top for being contacted with the surface of building panelling；With
For deforming basic matrix during extrusion operation and the protrusion of cavity being formed on the surface of building panelling
Portion.
The building panelling and manufacturing method of multiple embodiments according to the present invention can produce very advanced decoration figure
Case, the decorative pattern can be formed with the variable embossing being mutually aligned, the decoration which can apply with number be mutually aligned without
Generate repeating effect.
The embodiment and details of multiple and different schemes can be combined with the multiple embodiments and details of other schemes.
Description of the drawings
It is retouched in more detail hereinafter in connection with preferred embodiment and with reference to appended exemplary drawings to the present invention
It states, wherein：
Fig. 1 a-d show the known method of manufacture stamp and embossed surface；
Fig. 2 a-e show the repeating effect in the embossed surface according to known technology；
Fig. 3 a-f show the variable embossing according to an embodiment of the invention being mutually aligned；
Fig. 4 a-c show multiple embodiments of the present invention；
Fig. 5 a-d show multiple embodiments of the present invention.
Specific embodiment
Fig. 3 a-3f show multiple production stages of first scheme according to the present invention can be used for laminate flooring or its
The variable embossed surface being mutually aligned is formed in its floor, wherein the surface is formed and by squeezing preferably also through high temperature shape
Into.This method is based on such cardinal principle, i.e., wherein variable embossing is by digital sprayed coating curable ink or substance
What the mode of (also referred to as non-gloss ink) was formed, the curable ink or substance form in sprayed coating and after curing and are forced into substrate
On matrix, which is hereinafter referred to as ink matrix.
Fig. 3 a show laminated panel 1a, 1b, it includes the transparent mulch paper 18 being laid on HDF core plates 3 and have
The facing paper 5 of decoration.Laminated panel 1a, 1b includes the backing layer 4 for balancing panelling.It can be a part for wood grain structure
Stamp P1 be printed on by digital printer on the first panel 1a and different stamp P2 by digital printing second edge
On plate 1b.
Fig. 3 f show the panelling 1a and 1b after squeezing.A part of surface texture of described two panellings, that is, panelling 1a and 1b
It is manufactured in this embodiment in accordance with the invention using the identical basic matrix 40 (Fig. 3 c) of basis of formation embossing 17.This basis
It embosses and is combined with variable embossing 19a, the 19b formed in extrusion process through ink matrix 41a, 41b.The ink matrix passes through number
Curable ink 25a, 25b (also referred to as non-gloss ink) that code applies is formed.The curable ink is before pressing steps
It is cured into hardness of matter.
Fig. 3 b show that the pattern of two kinds of different curable ink 25a, 25b by being mutually aligned is applied to two prints
On flower P1, P2.Curable ink 25a, 25b is stretched out vertically upward from panel surface.Curable ink it is vertically extending
Height can be the scope from 0.05 millimeter to 0.5 millimeter, for example, about 0.1 millimeter, correspond to the normal floating of wood grain structure
Convex depth.
Fig. 3 c show curable ink 25a, 25b when it is cured into hard ink matrix 41a, 41b.Panelling
It is then moved in the extruder with pressing plate 24.
Fig. 3 d show that panelling and ink matrix 41a, 41b are extruded and heat, and are extruded so as to squeeze matrix 41a, 41b
Enter panel surface and pressing parameter that panel surface uses in laminate flooring and powder base Ban HuoLVT floors is preferably similar to
High fever and high pressure under be hardened.This method may be alternatively used for forming structure in wood materials and ceramic material.
Fig. 3 e show that they are included in ink matrix 41a, 41b on stamp P1, P2 when panelling leaves extruder.
Fig. 3 f show that ink matrix is subsequently removed and cavity 37a, 37b are formed on stamp P1, P2.Cavity
37a, 37b are formed as a part of variable embossing 19a, 19b.Panelling has embossed surface, which includes basis and emboss
17 and it is variable embossing 19a, 19b.The variable embossing is accurately aligned with variable digit printing P1, the P2.
Many polymer can be used to manufacture the curable ink 25 for being formed as ink matrix 41.Preferably ultraviolet light
Curable polymer.They include the polymer material of various different range, such as acrylic resin, acrylate, epoxy resin, poly-
Urethane, polyester and silicone.These materials can be applied by the use of piezoelectric print head as ink.They may be designed such that them not
Can be adhered to thermosetting property or thermoplastic surface such as melamine resin and vinyl, and they have enough intensity and
Heat resistance, this is desirable for being formed in being normally used for manufacturing the manufacturing step on floor of the above-mentioned type for body structure surface
's.Releasing agent can be comprised in curable ink, printed in surface or as individual before curable ink is by sprayed coating
Brush object applies.
High-quality and excellent performance can be obtained by water-based ultraviolet curing chemistry process, due to environmental factor thisization
Process is preferred embodiment.
It can be for example by by aliphatic or aromatic, propylene acid blocked, polyurethanes technology and polyester and/or propylene
The mode that sour material is combined prepares various curable inks to meet the specific requirements of different surfaces material.Water base purple
Outside line, which cures dispersion, can be formulated into curable ink or the painting of transparent and/or coloured low-luster and high gloss
Material.
The cardinal principle of digital curable ink sprayed coating method and apparatus is shown in fig.4.Including fixed digital print
The digital curable ink sprayed coating unit 36 of brush head 30 is by preferably transparent curable ink sprayed coating in mulch paper 18.Into
The sprayed coating of line number code with the mulch paper without generating any contact and ink 25 that this is curable is with from digital printing first 30 towards this
The drops sprayed coating of surface injection.
After ultraviolet curing oven 23 with ultraviolet light is preferably placed on digital sprayed coating unit 36 along feeding direction and make
Obtain that the curable ink 25 can almost instantaneous solidification into ink matrix 41, be in particular, for example being used with closing in seconds
In the case of the polyurethane coating of the ultraviolet curing of suitable Photoepolymerizationinitiater initiater.Preferably piezoelectricity makes the digital sprayed coating head of nozzle
30 preferably have the ability for the drop for ejecting the drop size with about 50-200 microlitres or bigger.Multiple rows of printing can be used
Head.The drop is preferably positioned to so that they are stacked on top of each other or be bonded to each other.
The ink of the ultraviolet-curing is preferably the water-based ultraviolet with the viscosity being adapted with digital sprayed coating first 30
Curable polyurethane mass.Water based polyurethane dispersion agent preferably uses in digital sprayed coating head as curable ink.With
Similar solvent-based coating is compared, they are more environmental-friendly and technology is more progressive.They for example without isocyanates and
With zero content or the low-down volatile organic matter of content.They have with hardness, coloring and wearability, impact strength and
The relevant excellent performance of temperature.
Polyurethane dispersant is the short grained polyurethane/polyurea reacted completely of discrete polymer and such particle can
It is made with about 0.01-5.0 microns of size and therefore can be used in digital piezoelectric print head or other similar print heads.
They can the solid content with 20-70% and many different layers with different hardness digital sprayed coating method can be utilized to be made.
Polyurethane dispersant for example can blend to reduce cost with acrylic emulsion and other emulsions.
Curable ink is stored in liquid form in container for paint 31, which can utilize coating feed pipe 32
It is connected to digital ink-jet first 30.The digital control unit that ink gun and conveyer belt are connected to using data cable 33 controls drop size
With the speed of the conveyer belt 21 compared with the first 30 movement panelling 1 of digital ink-jet.The sprayed coating equipment 36 of curable ink preferably connects
Digital printer is connected to, so that the pattern of curable ink is closed with the expectation decor made through digital printer.
Such number sprayed coating unit 36 more saves cost than digital printer, because digital sprayed coating unit 36 is sprayable
Go out much larger drop and its provide stronger productivity and reduce in the passage of print head there are the problem of, wherein this
A little passages may be shut when printing machine is worked using high-resolution and droplet by the larger particles in ink.Each
Ink gun may be designed to one layer of only sprayed coating and without coordinating different print heads as conventional digital printing.
Sprayed coating production line can closely and ultraviolet curing oven can to abut digital sprayed coating unit in place.Sprayed coating can be non-
It is often accurate.It surface comprising paper, powder, vinyl, thermoplastic film and analog can be by digital sprayed coating, to form advanced oil
Black matrix 41.Powder bed is steady using infrared lamp, hot-air or pre-extrusion preferably between the curable ink of sprayed coating
Surely ink change and that this permission is curable can be by sprayed coating to harder but still uncured powder surface.The powder can include
Wood-fibred or particle, adhesive are preferably resinoid and preferably also include abrasion resistant particles.
Digital sprayed coating equipment can have multiple ink guns certainly and panelling can be repeatedly below ink gun.Divided in coating
Into after multiple panellings, digital coating can be by sprayed coating to single multiple panellings or sprayed coating is on one big sheet material.
Ink matrix granule 41 can be used many modes and remove, and such as be moved by vacuum, air pressure, brush, promotion temperature, chemistry
Remove, removed using water etc..Curable ink can squeeze and heating makes its structure change into quilt after more little particle initial
It uses.
Considerably less amount can be used to provide advanced DVEIR surfaces.Only the surface of 5-10% can be capped 0.05 to 0.5
The mean depth of such as 0.1 millimeter of millimeter, and this means can only need 5-10 grams/m.Removed ink matrix material
Material can be recovered and be used in other applications as filler.
This method may be used to form the deep embossing with about 0.5 mm depth, and if use the curable of multilayer
There can be deeper depth if ink.
Fig. 4 b show the curable ink coating in the release paper or film 40 of substrate such as structuring, wherein curable
Ink 25 by sprayed coating to substrate 40 rather than in panel surface.This carrying method in basis embossing is formed by paillon
Rather than formed by pressing plate when be it is preferable to use.Can by pressing plate 24 as depicted or pressure cylinder (not shown) come
Apply pressure.Fig. 4 c show that the curable ink can be by sprayed coating on pressure cylinder or roller.The curable ink 25 can quilt
Be fixedly attached to the substrate or be transported to the surface only by substrate, wherein the curable ink in the next step from
It is removed on the surface.
Fig. 5 a-5d show DVEIR methods, can be used in a manner of very simple and low cost in nearly all class
Patterned structure is provided in the flooring material of type.
Fig. 5 a, 5b show substrate such as first foundation matrix material 40a, are preferably formed to one of underlying microstructure
Point.First foundation matrix material 40a is preferably delivered to outer feed roller 22b by extruder 24 from interior feed roller 22a.First base
Plinth matrix material 40a can be aluminium foil or plastic foil or coated and the release paper and analog of embossing.Such matrix
Material is generally applied in flooring industry and can provide a variety of microstructures with various luster degree.The second base can also be used
Plinth matrix 40b and its can be traditional pressing plate.Curable ink 25 is by digital sprayed coating unit 36 by sprayed coating to the first base
The back side of the plinth matrix 40a and curable ink 25 can be solidified into ink matrix 41 by ultraviolet curing oven 23.Fig. 5 c
Show that the on pressing plate 24 second basic matrix 40b compresses first foundation matrix 40a and the oil being pressed on first matrix 40a
Black matrix 41.Fig. 5 d show the surface texture when first foundation matrix 40a and ink matrix 41 are removed.Variable embossing 19
Cavity 37 is formed as by ink matrix 41 over surface 2 and is accurately aligned with stamp P.The surface further include by first and/
Or second basic matrix 40a, 40b the underlying microstructure 17a that is formed and basic boss structure 17b.
This method may be used to form basic matrix 40a, and basis matrix 40a can be provided in the form of coiled material or sheet material
And it be used to form embossed surface on building panelling.Basis matrix 40a can be aluminium foil as described above or plastic foil or
Person's coated paper.The basis matrix include to be extruded and from panel surface remove lower part and in extrusion process not with panelling table
Face contacts and includes the top of protrusion 41, which makes basic matrix 40a deform and under matrix during extrusion operation
Portion forms protrusion, and the protrusion forms cavity 37 in panel surface as shown in figures 5 b and 5 c.
It can be with the roller of heat and preferably pre- structuring come instead of extruder and pressing plate.Advanced DVEIR structures can be formed
In thermoplastic material as having in the floor of vinyl surface.
Above-mentioned all methods can be combined partly or entirely.
The separated type material that multiple embodiments of the present invention may be alternatively used for manufacturing traditional precreping is such as with coiled material or sheet material
Form is provided to floor factory to form the coated paper or paillon of coining matrix such as matrix material.Digital ink matrix may be formed at
On the upper side of precompressed floral material and/or downside.Even metal material can also be formed by etching, wherein digital ink-jet head
Sprayed coating can be used for etching and form the ink of embossed surface.
It is formed it will be appreciated by those skilled in the art that patterned structure can be formed only by ink matrix and be not necessarily to use
The pressing plate of the embossing processing of basic patterned structure or first or second basis matrix.The ink matrix being arranged in substrate can quilt
For substituting the pressing plate of traditional embossing processing.
The present invention multiple embodiments cardinal principle may be alternatively used for by before pressing steps by hard little particle
It lays on the surface and removes the mode of these particles after pressing to form embossed surface structure.These particles can be digital
Positioning.Pattern of adhesive or image can by ink gun it is digital be formed in substrate, the ink gun only sprayed coating can include water
Adhesive.Substrate can be powder bed, mulch paper or thermoplastic film or the like.Liquid adhesive can be by with can be included in
The mode of the adhesive reaction of such as melamine resin in surface or in hard particles make these particles directly or
It bonds indirectly.Hard little particle be by dispersal device in entire pattern of adhesive random dispersion.Adhesive bonding with
Liquid adhesive forms those particles of identical patterns, and other unbonded particles are for example blown away by air-flow.It is remaining
Particle forms the bulge-structure similar to cured curable ink.Substrate is subsequently extruded and cures and hard particles are pressed into
In the surface.Hard particles then by for example mechanically, by heat, air-flow or chemically remove.Hard particles can be husky, oxygen
Change aluminium or other minerals.Salt or sugar even can be used and final removal can be realized by using these particles of water dissolution.It is viscous
Mixture can be before hard particles be spread by digital sprayed coating.
Example：
Digital picture is applied in the powder based surface layer of the panelling comprising the HDF materials as core plate.Powder is wood
The mixture of fiber (40%), alumina particles (10%) and melamine resin (50%).Imagery exploitation single pass printer quilt
It generates and is injected into powder, which includes 5 fixed piezoelectric print heads.Ink is water base comprising pigment
Ink.Piezoelectric print head with 30 picoliters of drop sizes be used to utilize comprising the cured polyurethane of water-based ultraviolet
(PU) curable ink will be on the back side of matrix pattern sprayed coating to aluminium foil.The wood grain knot of the PU matrix pattern and digital picture
Structure is identical.The PU matrix patterns are solidified into ink matrix in ultraviolet furnace.The aluminium foil is located at the top of digit printing, so as to oil
Black matrix and digital picture are mutually aligned with each other.Panelling and with ink matrix aluminium foil in extruder in 40kg/cm2Pressure
Under be extruded 30 seconds and be heated to 160 DEG C.Aluminium profiles piece is removed after extrusion.It obtains with opposite with aluminium foil surface structure
The embossed surface being preferably mutually aligned for the basic glossiness answered.
Claims (9)
1. a kind of method that embossed surface (16) is formed in building panelling (1), comprises the following steps：
By using digital ink-jet head (30) by the surface of curable ink (25,25a, 25b) sprayed coating to building panelling (1)
The ink matrix (41,41a, 41b) with horizontal-extending size and vertical extension size is formed on layer (2)；
The ink matrix (41,41a, 41b) is squeezed by using basic matrix (40) compared with the superficial layer (2) to come on surface
Cavity (37) is formed on layer (2), so as to form the embossed surface (16) of the building panelling (1)；
By compared with superficial layer (2) squeeze the basic matrix (40) and in superficial layer (2) basis of formation emboss；With
The ink matrix (41,41a, 41b) is removed from the embossed surface (16).
2. according to the method described in claim 1, wherein, which is floor panel.
3. method according to claim 1 or 2, wherein, which includes the decorative layer (5) with stamp (P).
4. according to the method described in claim 3, wherein, which is mutually aligned with the stamp (P).
5. method according to claim 1 or 2, wherein, which is piezoelectric type nozzle.
6. method according to claim 1 or 2, wherein, which is polymer material.
7. method according to claim 1 or 2, wherein, this method, which further includes, cures the curable ink to form oil
Black matrix (41).
8. according to the method described in claim 3, wherein, which is digit printing (P).
9. according to the method described in claim 6, wherein, which is the polymer material of ultraviolet curing.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810418828.7A CN108394228B (en) | 2012-07-17 | 2013-07-12 | Mutually aligned digital embossing surfaces |
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201261672573P | 2012-07-17 | 2012-07-17 | |
| SE1250869-3 | 2012-07-17 | ||
| SE1250869 | 2012-07-17 | ||
| US61/672,573 | 2012-07-17 | ||
| PCT/SE2013/050900 WO2014014400A1 (en) | 2012-07-17 | 2013-07-12 | See extra sheet |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201810418828.7A Division CN108394228B (en) | 2012-07-17 | 2013-07-12 | Mutually aligned digital embossing surfaces |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN104684737A CN104684737A (en) | 2015-06-03 |
| CN104684737B true CN104684737B (en) | 2018-06-01 |
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| RU2801005C1 (en) * | 2022-12-29 | 2023-08-01 | Общество с ограниченной ответственностью "Колорплит" | Decorative panel manufacturing method and decorative panel |
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| EP2213476A1 (en) * | 2009-01-30 | 2010-08-04 | Spanolux N.V.- DIV. Balterio | A method of manufacturing a laminate panel, an apparatus and a laminate panel |
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| CN101626900A (en) * | 2007-02-02 | 2010-01-13 | S·D·沃伦公司 | The embossed surface of tip printing |
| CN101898484A (en) * | 2008-10-30 | 2010-12-01 | 乐金华奥斯株式会社 | Decoration sheet and method of manufacturing the same |
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