EP2722189A1 - Method for producing a decorated wall or floor panel - Google Patents

Abstract

The method involves providing a plate-shaped carrier (110). A decoration (130) is applied on a portion of the plate-shaped carrier. The decoration is template-identically applied by successively applying multiple decorative layers (131) with partially different surface applications based on provided three-dimensional decoration data i.e. electronic data. The three-dimensional decoration data are provided by a three-dimensional scanning of a decoration template. The decorative layers are applied by direct printing. The decorative layers are formed from radiation curable color and/or ink. An independent claim is also included for a decorated wall- and floor panel.

Description

The present invention relates to a method of making a decorated wall or floor panel, and to a wall or floor panel made according to such a method.

Such decorated panels are known per se, whereby the term wall panel is also to be understood as panels which are suitable for ceiling clothing. They usually consist of a support or core made of a solid material, for example a wood material, which is provided on at least one side with a decorative layer and a cover layer and optionally with other layers, for example, disposed between the decorative and cover layer wear layer. The decorative layer is usually a printed paper impregnated with an aminoplast resin. The cover layer and the remaining layers are usually made of aminoplast resin.

From the document US Pat. No. 6,888,147 B1 For example, a method of manufacturing a panel is known. In a method known from this document, a decoration is applied to a core, whereupon the decoration is provided with a lacquer layer. In order to achieve a structuring of the surface, for example, based on data obtained with a digital camera, for example, the uppermost lacquer layer is only partially applied.

However, in certain applications, and in particular in the requirement of highly detailed decorated panels, previously known panels may show one unsatisfactory decoration, especially if the imitation of a natural material such as wood or natural stone is desired.

It is therefore the object of the present invention to provide an improved method for the production of decorated wall or floor panels.

This object is achieved by a method according to claim 1. With regard to the wall or floor panel, the object is achieved by a panel according to claim 13.

1. a) Bereitstellen eines plattenförmigen Trägers,
2. b) Aufbringen eines eine Dekorvorlage nachbildenden Dekors auf zumindest einen Teilbereich des plattenförmigen Trägers,

welches dadurch gekennzeichnet ist, dass das Dekor vorlagenidentisch aufgebracht wird durch das sukzessive Aufbringen einer Mehrzahl an Dekorschichten mit zumindest teilweise unterschiedlichem Flächenauftrag auf Basis bereitgestellter dreidimensionaler Dekordaten.The invention thus proposes a method for producing a decorated wall or floor panel, comprising the method steps:

1. a) providing a plate-shaped carrier,
2. b) application of a decorative pattern replica decoration on at least a portion of the plate-shaped carrier,

which is characterized in that the decor is applied identical template by the successive application of a plurality of decorative layers with at least partially different surface application based on provided three-dimensional decor data.

It has been shown that the successive application of a plurality of decorative layers with at least partially different surface application on the basis of provided three-dimensional decor data can overcome the disadvantages known from the prior art with regard to the accuracy and detail of an imitation of the applied decoration.

The term "decorated wall or floor panel" or "decorative panel" are to be understood in the context of the invention, in particular wall, ceiling or floor panels, which have a decorative applied to a support plate decor. Decorative panels are doing in many ways, both in the field of interior design of rooms, as well as decorative cladding of buildings, for example in exhibition construction, used. One of the most common uses of decorative panels is their use as floor coverings. The decorative panels often have a decor that is intended to recreate a natural material.

Examples of such simulated natural materials are wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga panga, mahogany, bamboo and bubinga. In addition, many natural materials are modeled on stone surfaces or ceramic surfaces.

Correspondingly, a "decor template" in the sense of the present invention can be understood as meaning, in particular, such an original natural material or at least a surface of one which is to be imitated or imitated by the decor.

In the context of the present invention, the term "three-dimensional decor data" can furthermore be understood to mean in particular electronic data which reproduces the decor template on the basis of its three-dimensional size, color, structuring etc. and thus a complete physical or spatial haptic and visually identical or at least substantially identical Allow reproduction of the decor template. In this case, the three-dimensional decor data can be determined or generated directly from the decor template or artificially and thereby stored for example in a database for access. In addition, the three-dimensional decor data can in particular have a resolution in order to prevent differentiation, in particular by an optical or haptic comparison with the decor template by a human being, or only to a limited extent as desired.

For the purposes of the present invention, the term "template-identical" can also be understood as a highly detailed reproduction or imitation of the decorative template by the applied decoration. In this case, an imitation in each spatial direction or three-dimensionally be realized, but smallest deviations due to technical feasibility, such as deviations from the decoder data provided or from the decorative template, should be included by the term identical template. In addition, in the context of the present invention, the term "identical to a template" should not only encompass a color and / or structure that is positive, but also a corresponding negative image of the decorative template.

In the context of the present invention, a "plate-shaped carrier" can also be understood to mean a natural substance, such as a wood-based material, a fiber material or a material comprising a plastic, which is formed in the form of a plate and, in particular, as the core or base layer of the Serving panel can serve. For example, the plate-shaped carrier already give the panel a suitable stability or contribute to this. Furthermore, the plate-shaped carrier already pretend the shape and / or size of the panel to be produced. However, the plate-shaped carrier may also be provided as a large plate. A large plate according to the invention is in particular a carrier whose dimensions exceed the dimensions of the final decorative panels by a multiple and which is divided in the course of the manufacturing process into a corresponding plurality of decorative panels, for example by sawing, laser or water jet cutting.

Wood materials in the context of the invention are in addition to solid wood materials and materials such as cross-laminated timber, glued laminated timber, hardwood plywood, plywood, laminated veneer lumber, Funierstreifenholz and bending plywood. In addition, under wood materials in the context of the invention, wood chip materials such as chipboard, extruded plates, coarse chipboard (Oriented Structural Board, OSB) and chipboard wood as well as wood fiber materials such as wood fiber insulation boards (HFD), medium-hard and hard fiberboard (MB, HFH), and especially medium-density fiberboard (MDF) and high-density fiberboard (HDF) to understand. Also modern wood materials such as wood-polymer materials (WPC), sandwich panels of a lightweight core material such as foam, rigid foam or paper honeycomb and a wood layer applied thereto, as well as mineral, such as cement, bonded wood chipboard form wood materials in the context of the invention. Cork also represents a wood material in the context of the invention.

For the purposes of the invention, the term fiber materials means materials such as paper and nonwovens based on vegetable, animal, mineral or even artificial fibers, as well as cardboard. Examples are fibrous materials made of vegetable fibers, in addition to papers and webs of cellulose fibers, plates of biomass such as straw, maize straw, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers. Examples of animal fiber materials include keratin-based materials such as wool or horsehair. Examples of mineral fiber materials are mineral wool or glass wool.

Examples of thermoplastics are also polyvinyl chloride, polyolefins (for example polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), Polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof The plastics may contain conventional fillers, for example calcium carbonate (chalk), aluminum oxide, silica gel, quartz flour, wood flour, gypsum In particular, it may be provided that the carrier material has a flameproofing agent.

By the method described above, it is possible to imitate a decorative template in a particularly detailed and highly accurate manner in three-dimensional form or to feel. This is not only possible by imitating the two-dimensional shape of a pore or the like of a wood material, for example, with a uniform depth. Rather, a depth which is different in the pore or a depth distribution of the pore can also be possible, so that not only a template-like, but rather a template-identical reproduction of the decorative template by the decor is also possible in a three-dimensional manner. In other words, pores or other structural properties of the decorative pattern are not only in their width or length but also in their depth or depth distribution at different depths in a pore, for example, accurately and realistically replicable.

It is easily and with high precision possible without further steps to produce a matching with the decor image surface texturing. Under a matching with the decor image surface structuring is to be understood that the surface of the decorative panel has a haptic perceptible structure that corresponds to their shape and pattern of the appearance of the applied decor, so as to obtain a true to the original reproduction of a natural material also in terms of haptics ,

Such a product or wall or floor panel is produced by a template identical application of the decor by a plurality of decorative layers is applied successively with at least partially different surface application on the basis of provided three-dimensional decor data. Thus, the decor not only includes a layer, such as a printed paper layer, but rather is composed of a plurality of layers, the decorative layers. These layers are applied successively, that is, successively, to form the decor. Since these layers at least partially have a different surface order to each other, so not all decorative layers are applied with the same spatial extent, a specific and defined depth image or a defined depth perception can be generated by their different spatial extent. This not only a two-dimensional imitation of structural conditions of a decorative template is possible, but it is rather a three-dimensional and thus completely identical imitation of the decorative template realized in a particularly simple manner.

In this case, in particular by the use of digital decor data, a highly accurate formation of the decoration and thus a highly accurate perception impression of the manufactured panel may be possible. By providing digital decoder data, structuring can be imitated with an extremely high resolution and thus with the highest level of detail. Furthermore, by using digital decor data, it is particularly easy, cost-effective and dynamic to respond to changing customer requirements, since only new or changed decor data must be provided on the basis of which a product which in turn can be imitated in a highly accurate manner can be produced.

Furthermore, by the method described above in addition to a color and / or structure positive image further also a corresponding negative image of the decor template be possible. In detail, as is known, for example, from a positive pickling or negative pickling for wood materials, the color impression of, for example, a grain can be reversed by the use of digital data, so that a negative arises with respect to the color or, in particular, lighter and darker areas. The same is possible in addition to the color impression also for the applied structure, so that also with respect to the structural design, a negative is feasible. Even such effects can be easily integrated into a production process on the basis of digital three-dimensional data without any lead time or conversions.

Furthermore, a so-called heliochromic effect can be realized in a particularly advantageous manner by the method described above. For the purposes of the present invention, this can be understood in particular to mean that the decor has regions of different degrees of gloss, such as both matt and glossy regions, which can be arranged in particular at different depths of surface structuring. As a result, an even more realistic depiction of the decor template can be realized.

From the above, it is therefore apparent that the described method can make it possible to reproduce the decorative pattern better than the prior art and thus to produce a highly detailed product.

According to one embodiment of the method, the three-dimensional decor data can be provided by a three-dimensional scanning of the decor template. In particular, the three-dimensional decor data can be provided by a three-dimensional scanning of the decor template by means of electromagnetic radiation, for example by a three-dimensional scanner (3D scanner). By such a method of providing the three-dimensional decor data, the decor template can be immediately used at any time to provide the corresponding data and to produce a panel. This can be particularly advantageous for a particularly fast and dynamic changeover of production. In addition, the decor data can also be obtained three-dimensionally, ie in any spatial direction, with a particularly high resolution of, for example, 1000 dpi or even above, and used for producing the panel. As a result, a particularly high-quality detail is possible, which can make a special high-precision visual and haptic Nachempfinden the decorative template also three-dimensional. Furthermore, the three-dimensional data can be further generated without damaging the original, so that it can be used for a fundamentally unlimited number of scanning operations and can thereby provide unadulterated data.

According to a further embodiment of the method, the decorative layers can be formed from a particular radiation-curable ink and / or ink. For example, a UV-curable ink or ink may be used. In this embodiment, a particularly detailed and consistent replica of the decorative template can be achieved. For one thing, in this way can be achieved without the provision of further measures and highly accurate a synchronous pore. A synchronous pore can be in particular a pore or a different type of structure, which is spatially arranged exactly where it is optically represented by a haptic structuring matching the optical decor features. This is essentially the case automatically in this refinement, since the structural design is precisely produced by the ink or ink. In addition, decor templates, such as wood-based panels, often have a variation of the color impression not only along their width or length but also along their depth. Also, this color impression or color gradient can be modeled in particular detail in this embodiment, which also makes the overall impression of the panel appear even more identical. In this case, in particular the fact that the ink or radiation used is radiation-curable, achieve a particularly rapid solidification, whereby the plurality of layers can be applied to each other quickly, which can also make the overall process in a shorter time and thus can be particularly cost-effective.

In the context of the invention, the term radiation-curable ink is understood to mean a composition containing binder and / or filler as well as color pigments, which can be at least partially polymerized induced by electromagnetic radiation of suitable wavelength, such as UV radiation or electron radiation.

In the context of the invention, the term radiation-curable ink is correspondingly a composition which is essentially free of fillers and has color pigments understand which induced by electromagnetic radiation of suitable wavelength, such as UV radiation or electron beam, at least partially polymerized.

According to a further embodiment of the method, the decorative layers can be applied by direct printing. For the purposes of the invention, the term "direct printing" can be understood to mean the application of a decoration directly to the support of a panel or to a non-printed fiber material layer applied to the support. Contrary to conventional methods, in which a decorative layer previously printed with a desired décor is applied to a support, in the case of direct printing the printing of the decoration takes place directly in the course of the panel production. In this case, different printing techniques, such as flexographic printing, offset printing or screen printing can be used. In particular, digital printing techniques such as, for example, inkjet methods or laser printing methods can be used. The abovementioned printing processes are particularly mature and, in particular, advantageously suitable for panel production, in order to be able to apply a detailed decoration identical to a template. For the purposes of the invention, the application of the decoration by means of printing techniques to a print layer previously applied to the support is also to be understood by direct printing. Such a printable layer can be formed for example by a liquid applied and then cured primer layer or a previously applied printable film, paper or nonwoven layer.

In particular, a digital printing method may be suitable for the method described above, since the three-dimensional decor data are preferably provided in electronic form or in digital form. This may apply, for example, both for data stored in a database and for data determined in-situ by a three-dimensional scanner. Thus, the decoder data provided, in particular by digital printing process without further intermediate steps immediately be usable, which makes the method particularly in this embodiment with very little effort and cost applicable. In addition, by using digital printing methods, it is possible to perform each printing individually, so that a particularly wide range of applications and thereby dynamic adaptation to the desired product is possible.

According to a further embodiment of the method, the decor can be applied to at least a portion of a previously applied primer. In this case, the primer used may be a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, radical scavenger, leveling agent, defoamer or preservative, pigment and / or or a dye. For example, the urethane acrylate can be contained in the form of reactive oligomers or prepolymers in the primer composition. In the context of the invention, the term "reactive oligomer" or "prepolymer" is understood to mean a compound having urethane acrylate units which can be radiation-induced, optionally reactive to urethane polymer or urethane acrylate polymer with the addition of a reactive binder or a reactive diluent , Urethane acrylates in the context of the invention are compounds which are essentially composed of one or more aliphatic structural elements and urethane groups. Aliphatic structural elements include both alkylene groups, preferably having 4 to 10 carbon atoms, and cycloalkylene groups having preferably 6 to 20 carbon atoms. Both the alkylene and the cycloalkylene groups may be mono- or polysubstituted with C ₁ -C ₄ -alkyl, in particular with methyl, and may contain one or more non-adjacent oxygen atoms. The aliphatic structural elements are optionally connected to each other via quaternary or tertiary carbon atoms, via urea groups, biuret, urethdione, allophanate, cyanurate, urethane, ester or amide groups or via ether oxygen or amine nitrogen. Furthermore, urethane acrylates for the purposes of the invention may also include ethylenically unsaturated structural elements exhibit. These are preferably vinyl or allyl groups which may also be substituted by C ₁ -C ₄ -alkyl, in particular methyl, and which are derived in particular from α, β-ethylenically unsaturated carboxylic acids or their amides. Particularly preferred ethylenically unsaturated structural units are acryloyl and methacryloyl groups such as acrylamido and methacrylamido and especially acryloxy and methacryloxy. Radiation-curable in the sense of the invention means that the primer composition can be at least partially polymerized, induced by electromagnetic radiation of a suitable wavelength, such as, for example, UV radiation, or electron radiation.

The use of radiation-curable primers based on urethane acrylates makes it possible in a particularly advantageous manner to apply a decoration, for example by means of digital printing technology, immediately following the application and the radiation-induced curing of the primer layer. The primer layer ensures good adhesion of the applied decoration on the carrier surface coated with the primer. In this case, urethane acrylates have the advantage of good adhesion both to the support material and to the decorative layer, ie the decorative color or ink. This is due inter alia to the polymerization reactions occurring in this type of polymers, in which on the one hand a radiation-induced radical polymerization of the OH groups occurs, on the other hand, a post-curing of the polymer via the NCO groups. As a result, a tack-free and workable surface is obtained immediately after the radiation-induced curing, while the final properties of the primer layer are also influenced by the NCO group-based post-curing and ensure a secure bond to the substrate. In addition, the postcuring that occurs ensures that sufficient layer stability is achieved even in less or unexposed areas of the support. In this way, in particular, pre-structured carriers, that is to say carriers whose surface already has a three-dimensional structuring, can certainly be included in the process according to the invention Provided primer layer, which ensures that the subsequently applied decor is firmly bonded to the carrier.

The primer can preferably be applied in the process according to the invention by means of rubber rollers, casting machine, by spraying onto the carrier plate. The primer is preferably used in an amount between ≥ 1 g / m ² and ≦ 100 g / m ² , preferably between ≥ 10 g / m ² and ≦ 50 g / m ² , in particular between ≥ 20 g / m ² and ≦ 40 g / m ² applied. Following the application of the primer to the carrier surface, irradiation is carried out with a radiation source of suitable wavelength.

According to a further embodiment of the method, the decorative layers can each be applied in a thickness in a range of ≥ 5 μm to ≦ 10 μm. For example, the decorative layers can each be applied in a thickness in a range of 8 .mu.m. In particular, in this embodiment or with such thicknesses of the individual decorative layers can be achieved by a particularly thin design of the decorative layers and thus a highly precise variability of the surface application or the cover of a layer by the respective applied decorative layer a particularly template identical impression of the decor or the panel. In this case, all of the decorative layers to be applied may be in the above-mentioned thickness range, or such decorative layers may be located in the aforementioned thickness range, in the region of which highly precise structuring of the decorative original or the three-dimensional decorative data is predetermined. Other than the aforementioned decorative layers can be applied, for example, in thicker individual layers, if here a highly accurate structuring is not specified by the decorative template. Thus, the thickness of the applied decorative layers can be substantially adapted to the decor template and adjusted by the three-dimensional decor data. From the above it can be seen that even in this embodiment, a direct printing method can be particularly advantageous to the method to the corresponding concrete application such as in particular decor template or to be able to adapt to the desired product.

• c) Aufbringen einer Verschleiß- und/oder Deckschicht auf das Dekor.

According to a further embodiment of the method, the method may comprise the further method step:

• c) applying a wear and / or cover layer on the decor.

In this case, it is particularly preferred that a radiation-curable composition, such as, for example, a radiation-curable lacquer, such as an acrylic lacquer, is also applied to form the wear and / or cover layer. It can be provided that the wear layer hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, alumina (corundum), zirconium oxide or mixtures thereof, to increase the wear resistance of the layer. It may be provided that the hard material in an amount between 5 wt .-% and 40 wt .-%, preferably between 15 wt .-% and 25 wt .-% in the wear layer composition is included. The hard material preferably has an average particle diameter between 10 μm and 250 μm, more preferably between 10 μm and 100 μm. In this way, it is advantageously achieved that the wear layer composition forms a stable dispersion and segregation or settling of the hard material in the wear layer composition can be avoided.

To form a corresponding wear layer, it may be provided in one embodiment that the hard material-containing and radiation-curable composition in a concentration between 10 g / m ² and 250 g / m ² , preferably between 25 g / m ² and 100g / m ^{2 is} applied , In this case, the application can be applied for example by means of rollers, such as rubber rollers or by means of pouring devices.

It may be provided that the hard material at the time of application of the wear layer composition is not included in the composition, but is scattered as a particle on the applied wear layer composition and this is subsequently cured radiation-induced.

A wearing and / or covering layer in the sense of the invention is a layer applied as an outer finish, which in particular protects the decorative layer from wear or damage by dirt, moisture or mechanical effects such as abrasion.

According to a further embodiment, a carrier based on a natural material, a plastic or a wood-plastic composite material (WPC) can be provided. Depending on the desired physical properties of the finished plate, the carrier plate material can be massively dense or have cavities that are more or less large, for example foamed or have cavities whose size is of the order of the plate dimensions. It is also possible to use layer structures of a plurality of the stated materials, for example plasterboard or wood-plastic laminated boards.

For example, the carrier plate may be formed of a thermoplastic, elastomeric or thermosetting plastic. Also plates of minerals such as natural and artificial stone slabs, concrete slabs, gypsum fiberboards, so-called WPC plates (from a mixture of plastic and wood), as well as plates of natural raw materials such as cork and wood can be used according to the invention as a carrier. Also plates of biomass as natural material such as straw, corn straw, bamboo, foliage, algae extracts, hemp, oil palm fibers, can be used according to the invention. Furthermore, recycled materials from the materials mentioned can be used in the context of the method according to the invention For example, the panels may be based on the natural material cellulose, such as paper or cardboard.

Preferred as sheet material are thermoplastics such as polyvinyl chloride, polyolefins (for example, polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA ), Polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof The plastics can contain conventional fillers, for example calcium carbonate (chalk), aluminum oxide, silica gel, quartz flour, wood flour, gypsum In particular, it may be provided that the plate material has a flameproofing agent.

In particular, thermoplastics also offer the advantage that the products made from them can be recycled very easily. Recycled materials from other sources can also be used. This results in a further possibility for reducing the production costs.

According to a further embodiment, the plate-shaped carrier can be treated before and / or during process step b) with a means for reducing the electrostatic charge.

By providing a means for reducing the electrostatic charge, such as a means for dissipating electrostatic charges from the substrates to be printed, the occurrence of blurring during the production process can be avoided. This is particularly suitable for printing processes for applying the decorative layers, since the build up in the course of the production process electrostatic charge in the substrates to be printed to a deflection of the ink or ink drops on their way from Print head leads to the surface to be printed. It is assumed that the constituent electrostatic field on the carriers deflects the generally positively charged color particles so that they do not hit the intended point on the surface to be printed. The thus caused inaccuracy of the ink application leads to the noticeable blurring of the printed image. Depending on the production speed and the selected carrier material, this effect occurs to a different extent, so that it is assumed that the carriers, depending on the carrier material, are electrostatically charged by the transport within the production plant and this charge is sufficient to the observed effect cause.

In this case, the device for discharging electrostatic charges may comprise at least one roller, brush or lip made of a conductive material having a conductivity ≥ 1 * 10 ³ Sm ^-1 which electrically conductively contacts the carrier at least in the area of the printing unit and which is connected to an electrical ground potential is. In this case, the electrical ground potential can be provided for example by a ground.

According to a further embodiment of the method, it can be provided that at least partial steps of the method are carried out under an inert gas atmosphere. In particular, it may be provided that the method step of applying the decoration or the plurality of decorative layers is carried out under an inert gas atmosphere. Suitable inert gases are, for example, nitrogen, carbon dioxide, noble gases or mixtures of these.

In addition, the invention relates to a wall or floor panel, comprising a plate-shaped support, optionally a primer and a decorative pattern replica decor, which is characterized in that the decor has a plurality of decorative layers with at least partially different surface application, which are patterned identically.

In one embodiment of the wall or floor panel, the decorative layers are substantially, in particular completely, formed from a radiation-curable ink or ink layer. In this case, each of the layers may have a thickness in a range of ≥ 5 μm to ≦ 10 μm. Depending on the number of layers applied, the decoration and thus the sum of all decorative layers can have, for example, a layer thickness between ≥50 μm and ≦ 1 mm, preferably between ≥100 μm and ≤800 μm.

In a further embodiment of the wall or floor panel, the plate-shaped support can have a profiling, at least in one edge region, and the decoration can also be applied to the profiling. In a profiling according to the invention, it is provided that a decorative and / or functional profile is introduced by means of suitable material-removing tools at least in a part of the edges of the decorative panel. In this case, a functional profile is understood, for example, to mean the introduction of a tongue and / or groove profile into an edge in order to make decorative panels connectable to each other via the introduced profilings. A decorative profile in the sense of the invention is, for example, a chamfer introduced in the edge region of the decorative panel in order to simulate, for example, a joint between two interconnected panels, as occurs, for example, in so-called plank flooring.

In a partial profiling of the decorative panel not all to be provided in the final panel profiles are introduced, but only a part of the profiles to be provided, while other profiles are introduced in a subsequent step. For example, it may be provided that the decorative profile to be provided in a panel, such as a chamfer, is introduced in one work step, while the functional profile, for example tongue and groove, is introduced in a subsequent work step.

By applying the decoration only after the at least partial profiling of the carrier, for example by the above-described methods such as direct printing method, a removal or damage of the decoration in the course of profiling is advantageously avoided. As a result, the decor also corresponds to the desired imitation of a natural material, for example, in the areas of the profiling in a detailed manner.

In order to provide a particularly detailed imitation in the profiled areas, the print template used for printing in the area of the profiling of the panel can be distortion-compensated. Distortion compensation means in the sense of the invention, for example, for the exemplary case of application with a printing process, which is compensated by the deviation of the profiling from the surface plane of the carrier, for example at a chamfer flank, caused distortion of the printed image by adjusting the artwork to the deviation. It may be provided, for example, that the compensation of the distortion by means of adjustment of the pixel spacing, the pixel size and / or the ink application depending on the intended edge profile of the finished decorative panel. In the case of printing by means of digital printing, the triggering of the print head can take place as a function of the distortion to be compensated, so that the print head is deflected beyond the profiled area, for example, and the color output is adapted to the profile.

In this case, it is possible, for example, that prior to application of the decorative layer of the carrier provided as a large panel, the joints (such as V-joints) to be provided in a final panel composite are milled into the carrier, at least the decorative layer is applied to the carrier profiled in this way and the carrier is then divided at least in the profiled areas. Depending on the type of division, such as sawing, laser or water jet cutting, it may be preferred be provided that the required cutting allowance is taken into account in the introduced profile.

According to a further embodiment of the method, an additional profiling step can take place at least in a partial region of the edges of the decorative panel substantially parallel to the surface of the panel. As a result, for example, the functional profiles to be provided, such as tongue and groove, are introduced into the panel, whereby, for example, a mechanical locking, such as a hook lock, individual panels can be possible with each other. In the case of providing the carrier as a large plate, such an additional profiling step preferably takes place after the division into individual panels. If the carrier is already provided in the desired dimension of the single panel, such an additional profiling step can also take place simultaneously with the introduction of the other profiles, such as a chamfer.

On the decorative layer, a cover or wear layer may be applied. It may be provided in particular that the cover or wear layer is formed of radiation-cured paint. The covering or wear layer may, for example, have a layer thickness between ≥ 100 μm and ≦ 5 mm, preferably between ≥ 0.5 mm and ≦ 2.5 μm. Likewise, it can be provided that the wear and / or cover layer is laid on the printed support as a pre-produced overlay layer, for example based on melamine, and bonded thereto by pressure and / or heat.

• Fig. 1 zeigt schematisch ein erfindungsgemäßes Wand- oder Bodenpaneel in einer Draufsicht; und
• Fig. 2 zeigt schematisch das Wand- oder Bodenpaneel aus Figur 1 in einer geschnittenen Seitenansicht.

The invention is explained below with reference to the figures and an embodiment.

• Fig. 1 shows schematically a wall or floor panel according to the invention in a plan view; and
• Fig. 2 schematically shows the wall or floor panel FIG. 1 in a sectioned side view.

The Figures 1 and 2 The panel 110 comprises a plate-shaped carrier 110. The carrier 110 comprises or consists, for example, of a material based on a natural material, a plastic or a wood-plastic composite material (US Pat. WPC). For example, the carrier 110 is made of an extruded plastic material, such as polyethylene (PE), polypropylene (PP), polyamide (PA), polyurethane (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA). , Polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof.

On the carrier 110, a decor 130 is applied, which is intended to imitate a decorative template. The decor 130 is applied by suitable printing methods such as screen printing, digital printing, flexographic printing or offset printing. On the plate-shaped support 110, a layer comprising a primer 120 is further applied prior to the application of the decor 130, which has in particular a radiation-cured polyurethane acrylate or polyurethane.

In the decor 130, for example, a natural wood material modeled surface structures 111 based on provided three-dimensional decor data, such as provided by a three-dimensional scanning of the decor template, incorporated. In order to make surface patterns 111 of the decor template not only in their width or length but also in their depth or depth distribution accurate and realistic and thus template identical, the decor 130 is applied with a plurality of decorative layers 131 with at least partially different surface application, with respect to the decor template Template identical structured. The decorative layers 131 are formed from a particular radiation-curable ink and / or ink and each have a thickness in a range of ≥ 5μm to ≤ 10μm.

To increase the wear resistance can be applied to the decor 130, a cover layer, not shown, and / or hard material-containing wear layer, wherein the cover and / or wear layer are formed in particular by a radiation-cured paint layer.

Furthermore, the wall or floor panel 100 or its plate-shaped support 110 can have a profiling, at least in one edge region, and the decor 130 can also be applied to the profiling.

Claims (15)

Method for producing a decorated wall or floor panel (100), comprising the method steps: a) providing a plate-shaped carrier (110), b) applying a decorative template (130) to at least a partial region of the plate-shaped carrier (110),
characterized in that the decor (130) is applied identical to the template by the successive application of a plurality of decorative layers (131) with at least partially different surface application on the basis of provided three-dimensional decor data. The method of claim 1, wherein the three-dimensional decor data is provided by three-dimensional scanning of the decor template. Method according to one of claims 1 or 2, wherein the decorative layers (131) are formed from a particular radiation-curable ink and / or ink. Method according to one of the preceding claims, wherein the decorative layers (131) are applied by direct printing. Method according to one of the preceding claims, wherein the decor (130) is applied to at least a portion of a previously applied primer (120). A method according to claim 5, wherein the primer (120) used is a liquid radiation-curing mixture based on a urethane or a urethane acrylate. Method according to one of the preceding claims, wherein the decorative layers (131) are each applied in a thickness in a range of ≥ 5μm to ≤ 10μm. Method according to one of the preceding claims, comprising the further method step c) applying a wear and / or cover layer on the decor (130). A method according to claim 8, wherein a hardstoffhaltiger radiation and / or thermosetting paint is applied as a wear layer. Method according to one of the preceding claims, wherein a support (110) based on a natural material, a plastic or a wood-plastic composite material (WPC) is provided. A method according to claim 10, wherein a support (110) based on a thermoplastic selected from the group consisting of polyvinyl chloride, polyolefin (for example polyethylene (PE), polypropylene (PP), polyamide (PA), polyurethane (PU), polystyrene (PS ), Acrylonitrile-butadiene-styrene (ABS), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK), or blends or co-polymers thereof. Method according to one of the preceding claims, wherein the plate-shaped carrier (110) before and / or during process step b) is treated with a means for reducing the electrostatic charge. Wall or floor panel, comprising a plate-shaped support (110), optionally a primer (120) and a decoration reproducing a decor template (130), characterized in that the decor (130) has a plurality of decorative layers (131) with at least partially different surface application, which are patterned identically. Wall or floor panel according to claim 13, wherein the decorative layers (131) are formed essentially of a radiation-curable ink or ink layer. Wall or floor panel according to one of the preceding claims, wherein the plate-shaped support (110) has a profiling at least in one edge region, and wherein the decor (130) is also applied to the profiling.

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