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EP3539792B1 - Method for creating structures on a substrate - Google Patents

Method for creating structures on a substrate Download PDF

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Publication number
EP3539792B1
EP3539792B1 EP18162046.9A EP18162046A EP3539792B1 EP 3539792 B1 EP3539792 B1 EP 3539792B1 EP 18162046 A EP18162046 A EP 18162046A EP 3539792 B1 EP3539792 B1 EP 3539792B1
Authority
EP
European Patent Office
Prior art keywords
substrate
decoration
film
providing film
optimized
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18162046.9A
Other languages
German (de)
French (fr)
Other versions
EP3539792A1 (en
Inventor
Pius Steinmann
Vito Monteleone
Oliver Grossmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Swiss Krono Tec AG
Original Assignee
Swiss Krono Tec AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Swiss Krono Tec AG filed Critical Swiss Krono Tec AG
Priority to PL18162046T priority Critical patent/PL3539792T3/en
Priority to EP18162046.9A priority patent/EP3539792B1/en
Priority to PT18162046T priority patent/PT3539792T/en
Priority to ES18162046T priority patent/ES2894945T3/en
Publication of EP3539792A1 publication Critical patent/EP3539792A1/en
Application granted granted Critical
Publication of EP3539792B1 publication Critical patent/EP3539792B1/en
Active legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
    • B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
    • B44B5/02—Dies; Accessories
    • B44B5/026—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B44C3/025—Superimposing layers to produce ornamental relief structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers

Definitions

  • the invention relates to a method for producing structures on a substrate.
  • the production of structures on a substrate in particular on paper or wood material surfaces, is known per se.
  • the EP 2 179 863 A1 the decorating, but also the structuring of a substrate by means of a structuring foil. This process is well suited for small quantities, but the cost of the structure generator film is too high for mass products.
  • US 2009/151866 A1 discloses a method for producing a structure on a substrate, wherein a decoration is printed on a substrate, and a corresponding three-dimensional structure is produced on a test press plate. Then the printed substrate is embossed with the test press plate. If the print decoration and the structure do not match, a new test press plate is produced and tested.
  • WO 2014/014400 A1 discloses a method whereby a three-dimensional structure is printed onto a film with curable ink. The film provided with the structure is then fed to a press, where the pressure side of the structured film is pressed against a decorated substrate in order to emboss the structure in the substrate surface.
  • the object of the invention is to propose a flexible method for producing structures on a substrate that is suitable for both small and large quantities.
  • the structure to be transferred to the substrate can first be transferred to the substrate quickly and inexpensively by means of a structure donor foil.
  • the structure can be optimized if necessary, details are explained below.
  • patterns or smaller orders for the substrate can be created quickly, easily and at low cost by means of structure donor foil.
  • the fast and inexpensive production of patterns allows z. B. to check customers or sales staff, decor and structure and also check or test suggestions for improvement until the desired optimum is achieved.
  • the optimized structure is transferred to a press plate and transferred from the press plate to the substrate.
  • the more economical press plate preferably a press plate made of stainless steel, is used for larger quantities.
  • the risk of the structure not being able to fit the first time the press sheet is produced is eliminated by the described lead time.
  • the file in which the optimized structure is saved is used to manufacture the press plate. This ensures that the optimized structure is also used reliably for the production of large quantities of a substrate that is provided with a decoration and a structure.
  • press plates are only produced if the structure is actually in demand and it is certain that there is sufficient demand to justify the production of an expensive press plate. In this way, not only are costs better allocated and thus reduced overall, but there are also fewer press plates in the warehouse, which simplifies storage.
  • the decor and structure are advantageously matched to one another, especially in the case of decors and structures that imitate natural materials such as wood or stone.
  • the structure can be optimized, in particular to match the decor.
  • the optimization takes place if the structure does not yet meet the requirements by changing the structure, either directly on the computer by editing the file or by editing the printed structure and rescanning it, then saving it as a new file and then producing a new structuring film with the changed structure.
  • This changed structure is then printed again on a substrate provided with the associated decoration and assessed again. If necessary, the optimization steps are repeated.
  • the decoration on the substrate can also be optimized by either changing the decoration on the computer by editing the file or rescanning a printed decoration and saving it as a new file in order to then print it on the substrate to become. Printing is preferably done with digital printers, e.g. B. laser or inkjet printers.
  • the structuring film is produced by printing, preferably by using a structure-giving medium, e.g. B. ink, pigments or particles can be applied to a film by means of a printer.
  • the structure-giving medium can preferably be used in a digital application device, e.g. B. a 3D printer, a laser printer or an inkjet printer.
  • the medium can be processed as a solid or in liquid form.
  • the structure-giving medium is preferably applied in solid or liquid form by means of a digital printer, in particular an inkjet printer, a laser printer, a 2-D or 3-D printer. The medium is applied to the structuring foil and bound there.
  • the medium is applied not only as a layer on the surface of the structure generator film, but as an elevation that protrudes beyond the surface of the film.
  • this creates a three-dimensional structure that, depending on the type of medium used, still has to dry, set or harden, e.g. B. by exposure to temperature or radiation such as laser or UV light or electron beams.
  • the structure applied to the embossing side of the structuring foil is sufficiently strong to emboss the surface of a substrate.
  • the height of the structure can preferably be from 1 ⁇ m to 1000 ⁇ m. It can vary in order to reproduce a given model in great detail.
  • the minimum height results from the minimum application amount of the structure-giving medium that the application device can at least process, the maximum application amount results from the maximum embossing that can be made in the surface of the substrate. For example, repeating patterns or individual images (silhouettes of people, objects or areas such as city silhouettes), but also replicas of natural objects such as. B. wood grain, bark replicas or images of plants can be applied as a structure to the structuring foil.
  • the structure is usually applied to the structure generator film on the basis of a digital data record. It is advantageous that, for example, in the case of lifelike reproductions of wood grains, the same digital data set that is used to produce the structure can also be used to create a decorative film, e.g. B. to print a paper film or a plastic film with a two-dimensional decor in color. After or before the creation of the decoration, the corresponding structure is printed raised on the film with the identical data record. In this way, substrates can be made uniform, e.g. B. a decorative film or a decorative paper can be laminated onto the substrate, then either the decorative film or a further coating that is applied to the decorative film can be provided with a three-dimensional structure by means of the structuring film.
  • a foil for single use or a reusable foil can be produced. This means that samples, individual orders and small series can be produced economically.
  • a high-resolution structure can be generated.
  • details of the structure can be applied in a resolution of 25 dpi to 4800 dpi.
  • the structure-giving medium can be applied very differently and finely distributed in different thicknesses to the print side of the structure-forming film.
  • the three-dimensional structure that is generated on the print side of the structure generator film can be applied with different thicknesses, based on the surface of the print side, from approx. 1 ⁇ m to approx. 1000 ⁇ m, so that pronounced relief-like structures can be applied, which are mostly tactile on the surface of the substrate.
  • the structuring film can be selected from a variety of materials.
  • the structuring film can, for. B. made of metal, in particular aluminum. It can also be made of plastic, paper, cardboard or a composite material. It can have one or more layers. If the structuring film is made of plastic, it preferably has one or a combination of the plastics listed below: polyethylene, high-density polyethylene, polypropylene, polyethylene terephthalate, polyurethane, thermoplastic polyurethane, polyacetate, polycarbonate, polyimide, polystyrene, polyvinyl chloride or polytetrafluoroethylene. Mixtures of the aforementioned materials can also be used to produce the structure generator film, e.g. B. Mixtures of different plastics or layers of different materials.
  • the structure generator film can also have a coating, e.g. B. a varnish or a primer.
  • the coating can, for example, improve the adhesion of the structure-imparting medium to the structure donor film or it can influence the surface properties of the structure donor film, e.g. B. enable a matt or high-gloss surface.
  • At least the print side of the structure generator film can have a matt or glossy to high gloss surface. Accordingly, the print side creates a matt or glossy or high-gloss surface on the substrate.
  • a solid or liquid medium is e.g. B. applied by a 3D printer, a laser printer or an inkjet printer on the print side of a film, which becomes the structure generator film.
  • the structure-giving medium is inextricably linked to the printing side of the film, so that it remains completely adhered to the printing side during the embossing and also during the removal of the structure-giving film from the substrate.
  • This can e.g. B. happen that the structure-giving medium adheres to the print side by drying, for example by evaporating water or solvent.
  • the medium can harden if, for. B.
  • a medium processed by a 3D printer is applied in the form of solid particles and z.
  • the structure applied to the print side which is shown as a negative after the embossing in the surface of the substrate, can either be a self-contained motif, but it can also reproduce a motif several times or it can only reproduce part of a motif.
  • z. B. wood structures or other natural structures such as B. Stone structures shown.
  • any other motifs such as B. logos, skylines or the like can be produced.
  • further information is applied to the print side regardless of the motif, e.g. B. print marks or other information that relate to the alignment of the structure generator film with respect to the substrate or a press in which the structure generator film and the substrate are pressed in order to transfer the structure to the surface of the substrate.
  • This information can also, since it is transferred to the surface of the substrate, be used for later processing steps of the substrate, e.g. B. to provide information on dividing the substrate into individual parts.
  • This additional information can also be applied by the digital application device or it can be applied by other application devices.
  • the application of a structure to the surface of a substrate comprises the steps of providing a substrate with a surface and of providing a structure generator film with a print side, onto which at least in sections a structure is applied giving medium that forms a structure.
  • the method further comprises placing the print side of the structure donor film on the surface of the substrate and pressing the substrate and structure donor film in a press, the structure applied to the print side of the structure donor film being impressed on the surface of the substrate, since in the Press smooth, non-structured press plates are used.
  • the structure-giving medium applied to the printing side of the structure generator film thus comes into direct contact with the surface of the substrate in order to produce a negative of the structure applied to the printing side there.
  • the surface of the substrate is embossed in a relief-like manner and thus likewise shows a structure.
  • the pressure of the press is required to emboss the structure into the surface of the substrate.
  • the pressure is usually from 10 N / mm 2 to 1000 N / mm 2 .
  • an increased temperature is also used so that the surface of the substrate can be more easily deformed.
  • the temperature is e.g. B. from 40 ° C to 300 ° C, preferably from 140 ° C to 200 ° C.
  • the pressure is applied by a press, usually a short-cycle press (KT press) or by a continuous press.
  • a press duration of a maximum of 150 seconds is sufficient, usually 10 seconds to 30 seconds are sufficient, at least a press duration of 5 seconds is sufficient to depict the structure on the print side of the structure generator film as a negative, and thus also as a structure on the surface of the substrate .
  • the pressing conditions are selected depending on the substrate to be embossed. The expert determines the optimal pressing conditions with a few preliminary experiments.
  • All materials that can be embossed by the structuring foil are suitable as the substrate, typically wood or wood-based materials, plastics, in particular thermoplastic plastics, metals, in particular metal foils, but also ceramic materials. Wood fiber or chipboard, plywood, laminated wood and OSB boards are among the wood-based materials that are referred to as wood-based materials in the context of the invention.
  • the materials can also be used as an intermediate product, e.g. B. before or during drying, pressing or curing, if they are in are in a manufacturing state in which they are still soft enough to be embossed.
  • the materials can also be heated or temporarily softened in some other way in order to enable the surface to be embossed.
  • the substrate has a surface coating which is embossed by the structure donor film.
  • This surface coating which then forms the surface of the substrate, can preferably consist of a lacquer or a synthetic resin. Lacquer or synthetic resin can advantageously be highly viscous or dried, but not yet hardened. Also gelled paints, e.g. B. UV or radiation-curing lacquers can be easily embossed through the structure donor film, so that the surface coating as a structure shows an exact and detailed negative of the structure applied to the print side of the structure donor film.
  • Typical synthetic resin coatings can be well suited as a surface coating of a substrate in order to be pressed with the structuring foil according to the invention, in particular if the press is operated at a pressing temperature of approx. 140 ° C to approx. 200 ° C.
  • the synthetic resin is preferably used as a precondensed or dried but not yet cured surface coating, e.g. B. used by wood-based panels. It liquefies in the press at the temperatures mentioned. In this state it can be embossed through the structuring foil. In the further course of the pressing process, the synthetic resin hardens at the temperatures mentioned, so that a permanent structure can be embossed into the surface.
  • Typical synthetic resins are melamine resin, phenol-formaldehyde resin and urea resins.
  • lacquers can also be used without further ado. Frequently used lacquers are acrylate- or methacrylate-based lacquers, polyurethane lacquers, epoxy lacquers, or water-based lacquers. UV- or radiation-curing lacquers and thermosetting lacquers are preferably used because these lacquers can be gelled (partially cured) in a precisely tailored match to the structure donor film according to the invention, so that after the pressing process an optimal reproduction of the structure of the structure donor film is reproduced in the lacquer surface, e.g. . B. because the paint is not more dissipates. The paint can be completely cured during or after the pressing process.
  • the file with the possibly optimized structure is used according to the invention to produce a press plate and that Press plate structured in this way is used in the press instead of a non-structured press plate.
  • the conditions for pressing are usually the same as for embossing the structure with a structuring foil.
  • Fig. 1 a flow chart of the method according to the invention
  • the inventive method begins to present a decor provided with a structure, for. B. a wood or stone surface or an artificially designed surface.
  • the decor and then the structure are then scanned and stored in separate files.
  • the resolution can range from 25 dpi (dots per inch) to 4800 dpi.
  • the decoration is applied to the substrate according to the data stored in the respective file, e.g. B. a decorative paper or the surface of a wood-based panel, in particular a wood-based panel with a synthetic resin layer applied to it, printed.
  • a digital printer e.g. B. a laser printer or an inkjet printer is used.
  • the structure saved in the respective file is printed on a structuring foil.
  • the structuring film is made of a plastic, here PET (polyethylene terephthalate). However, it can be made from a wide range of materials, including various plastics, metal, paper, or cardboard Includes composite materials. Suitable plastics are listed in the general description.
  • the structure is applied to the structure generator film by means of a digital printer, e.g. B.
  • a laser or inkjet printer that prints structures in a layer thickness of 1 ⁇ m to 1000 ⁇ m on the PET film.
  • the ink or another medium applied by means of the printer adheres firmly to the film and has a density that is suitable for embossing a substrate with a decoration applied to it.
  • the structure is then embossed onto the substrate provided with the decoration by means of the structure generator film.
  • a stack of pressed material consisting of the substrate, which is provided with a decoration, and the structure generator film is introduced into the press.
  • the substrate is an 8 mm fibreboard and the decor is applied as a synthetic resin-impregnated decor paper on a top side of the fibreboard.
  • the stack of pressed material is pressed between smooth, non-structured press plates.
  • the embossing is preferably carried out in a short-cycle press (KT press). In the simplest case, only the pressure of the press is required to emboss the structure into the surface of the substrate.
  • the pressure is usually from 10 N / mm 2 to 1000 N / mm 2 .
  • an increased temperature is also used so that the surface of the substrate can be more easily deformed.
  • the temperature is usually in a range from 40.degree. C. to 300.degree. C., preferably from 140.degree. C. to 200.degree. C., in the present case 160.degree.
  • the decor and the structure - as in the present exemplary embodiment - are matched to one another, then after a first pressing of the structure onto the decor it is to be checked whether the structure and the decor are optimally matched to one another. In addition, it must be checked whether the structure that was originally removed from the original is also optimal in the pressed version or whether there is still a need for optimization, e.g. B. in the coloring, in the precision of the coordination with the decor or the arrangement and execution of the structure with regard to the depth of the embossing. The same goes for the decor. Even if the decor seemed well suited as a template, the finished pressed version should be checked to see whether there is any need for further optimization, e.g. B. in the adaptation of the color scheme, the improvement of shading or the sharpness of the contours.
  • the files for the structure and the decor are revised and adapted according to the need for optimization if the changes can be made directly to the file using a computer. If not, a printout of the structure and / or the decor is printed out, edited and scanned again so that a modified file is available in each case.
  • the structure is printed out again on a structure generator film according to the adapted file and pressed onto a substrate with decoration as described above. If the decor has also been adapted, the adapted decor is also printed on the substrate beforehand so that it can be checked whether the changed version of the structure and, if applicable, the decor match one another. This process can be repeated until the result is satisfactorily optimized. It is obvious that the production of a structuring foil is quick and uncomplicated and much cheaper in relation to even small test press plates of approx. 50 cm x 50 cm.
  • Test prints and small individual orders can be produced using the structuring foil alone.
  • larger quantities of substrates provided with a structure can be produced more economically by using a structured press plate.
  • the optimized file is used to produce a structured press sheet so that large quantities of a substrate provided with a structure can also be produced economically.
  • structured press plates are only produced if it is actually economical, whereas previously it had to be speculated whether the production of a certain structured press plate is economically viable.
  • stocking structured press plates is much easier because only those press plates are produced that are actually required for the production of large quantities of structured substrates.

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  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Herstellen von Strukturen auf einem Substrat. Das Herstellen von Strukturen auf einem Substrat, insbesondere auf Papier- oder Holzwerkstoffoberflächen ist an sich bekannt. Beispielsweise beschreibt die EP 2 179 863 A1 das Dekorieren, aber auch das Strukturieren eines Substrats mittels einer Strukturgeberfolie. Dieses Verfahren ist gut für kleine Stückzahlen geeignet, für Massenprodukte sind die Kosten der Strukturgeberfolie jedoch zu hoch. US 2009/151866 A1 offenbart ein Verfahren zum Herstellen einer Struktur auf einem Substrat, wobei ein Dekor auf ein Substrat gedruckt wird, und eine entsprechende dreidimensionale Struktur auf einem Probe-Pressblech hergestellt wird. Danach wird das bedruckte Substrat mit dem Probe-Pressblech geprägt. Falls das Druckdekor und die Struktur nicht übereinstimmen, wird ein neues Probe-Pressblech hergestellt und getestet. Letztendlich wird ein endgültiges, vollformatiges, Pressblech mit der optimierten Struktur hergestellt, das dann zur Laminatherstellung verwendet wird. WO 2014/014400 A1 offenbart ein Verfahren, wobei eine dreidimensionale Struktur mit härtbarer Tinte auf eine Folie gedruckt wird. Die mit der Struktur versehenen Folie wird sodann einer Presse zugeführt, wo die Druckseite der strukturierten Folie gegen ein dekoriertes Substrat gedrückt wird, um die Struktur in der Substratoberfläche einzuprägen.The invention relates to a method for producing structures on a substrate. The production of structures on a substrate, in particular on paper or wood material surfaces, is known per se. For example, describes the EP 2 179 863 A1 the decorating, but also the structuring of a substrate by means of a structuring foil. This process is well suited for small quantities, but the cost of the structure generator film is too high for mass products. US 2009/151866 A1 discloses a method for producing a structure on a substrate, wherein a decoration is printed on a substrate, and a corresponding three-dimensional structure is produced on a test press plate. Then the printed substrate is embossed with the test press plate. If the print decoration and the structure do not match, a new test press plate is produced and tested. Ultimately, a final, full-size, pressed sheet with the optimized structure is produced, which is then used to produce the laminate. WO 2014/014400 A1 discloses a method whereby a three-dimensional structure is printed onto a film with curable ink. The film provided with the structure is then fed to a press, where the pressure side of the structured film is pressed against a decorated substrate in order to emboss the structure in the substrate surface.

Die Aufgabe der Erfindung liegt darin, ein flexibles Verfahren zum Herstellen von Strukturen auf einem Substrat vorzuschlagen, das sowohl für kleine als auch für große Stückzahlen geeignet ist.The object of the invention is to propose a flexible method for producing structures on a substrate that is suitable for both small and large quantities.

Diese Aufgabe wird gelöst mit einem Verfahren nach Anspruch 1.This object is achieved with a method according to claim 1.

Die erfindungsgemäße Lösung sieht ein Verfahren vor, bei dem zum Herstellen von Strukturen folgende Schritte vorgesehen sind:

  • das Vorlegen eines Dekors, das mit einer Struktur versehen ist,
  • das Scannen des Dekors und der Struktur und das Speichern in separaten Dateien,
  • das Drucken des Dekors auf ein Substrat,
  • das Drucken der Struktur auf eine Strukturgeberfolie,
  • das Prägen der Struktur mittels der Strukturgeberfolien auf ein mit dem Dekor versehenes Substrat,
  • ggf. das Optimieren der Struktur und erneutes Drucken der Struktur auf eine Strukturgeberfolie und Prägen der Struktur mittels der Strukturgeberfolie auf ein mit dem Dekor versehenes Substrat und
  • das Übertragen der ggf. optimierten Struktur auf ein Prägeblech.
The solution according to the invention provides a method in which the following steps are provided for producing structures:
  • the submission of a decor that is provided with a structure,
  • scanning of the decor and structure and saving in separate files,
  • printing the decoration on a substrate,
  • the printing of the structure on a structuring foil,
  • the embossing of the structure by means of the structure donor foils on a substrate provided with the decoration,
  • optionally optimizing the structure and reprinting the structure on a structure donor foil and embossing the structure by means of the structure donor foil on a substrate provided with the decoration and
  • transferring the possibly optimized structure to an embossing plate.

Mit dem erfindungsgemäßen Verfahren kann die auf das Substrat zu übertragende Struktur zunächst schnell und preiswert mittels Strukturgeberfolie auf das Substrat übertragen werden. Die Struktur kann bei Bedarf optimiert werden, Details dazu werden nachfolgend erläutert. Damit können auf einfache Weise Muster oder kleinere Aufträge für das Substrat mittels Strukturgeberfolie schnell, unkompliziert und zu geringen Kosten erstellt werden. Insbesondere die schnelle und preiswerte Herstellung von Mustern erlaubt es z. B. Kunden oder Vertriebsmitarbeitern, Dekor und Struktur zu prüfen und Verbesserungsvorschläge ebenfalls zu prüfen bzw. zu testen, bis das gewünschte Optimum erreicht ist.With the method according to the invention, the structure to be transferred to the substrate can first be transferred to the substrate quickly and inexpensively by means of a structure donor foil. The structure can be optimized if necessary, details are explained below. In this way, patterns or smaller orders for the substrate can be created quickly, easily and at low cost by means of structure donor foil. In particular, the fast and inexpensive production of patterns allows z. B. to check customers or sales staff, decor and structure and also check or test suggestions for improvement until the desired optimum is achieved.

Wenn das gewünschte Optimum erreicht ist und wenn Dekor und Struktur in größeren Mengen produziert werden sollen, wird die optimierte Struktur auf ein Pressblech übertragen und vom Pressblech auf das Substrat übertragen. Damit wird für die größeren Mengen das in diesem Fall wirtschaftlichere Pressblech, bevorzugt ein Pressblech aus Edelstahl eingesetzt. Das Risiko, dass die Struktur beim ersten Herstellen des Pressblechs doch nicht passen könnte, ist durch den geschilderten Vorlauf ausgeschlossen. Die Datei, in der die optimierte Struktur gespeichert ist, wird zum Herstellen des Pressblechs verwendet. Damit ist gewährleistet, dass die optimierte Struktur zuverlässig auch zur Herstellung großer Mengen eines Substrats eingesetzt wird, das mit einem Dekor und mit einer Struktur versehen ist. Zugleich werden nur noch dann Pressbleche gefertigt, wenn die Struktur tatsächlich nachgefragt ist und gesichert ist, dass ausreichend Nachfrage besteht, um die Herstellung eines kostenintensiven Pressblechs zu rechtfertigen. Damit werden nicht nur Kosten besser zugeordnet und dadurch insgesamt gesenkt, vielmehr befinden sich auch weniger Pressbleche am Lager, was die Lagerhaltung vereinfacht.When the desired optimum has been achieved and when decor and structure are to be produced in larger quantities, the optimized structure is transferred to a press plate and transferred from the press plate to the substrate. In this case, the more economical press plate, preferably a press plate made of stainless steel, is used for larger quantities. The risk of the structure not being able to fit the first time the press sheet is produced is eliminated by the described lead time. The file in which the optimized structure is saved is used to manufacture the press plate. This ensures that the optimized structure is also used reliably for the production of large quantities of a substrate that is provided with a decoration and a structure. At the same time, press plates are only produced if the structure is actually in demand and it is certain that there is sufficient demand to justify the production of an expensive press plate. In this way, not only are costs better allocated and thus reduced overall, but there are also fewer press plates in the warehouse, which simplifies storage.

Vorteilhaft sind Dekor und Struktur aufeinander abgestimmt, insbesondere bei Dekoren und Strukturen, die Naturstoffe wie Holz oder Stein nachahmen.The decor and structure are advantageously matched to one another, especially in the case of decors and structures that imitate natural materials such as wood or stone.

Nach einer weiter vorteilhaften Ausführung kann eine Optimierung der Struktur, insbesondere zur Abstimmung auf das Dekor, erfolgen. Die Optimierung erfolgt, wenn die Struktur den Anforderungen noch nicht genügt, indem die Struktur verändert wird, entweder direkt am Rechner durch Bearbeiten der Datei oder aber indem die ausgedruckte Struktur bearbeitet und neu gescannt wird, sodann als neue Datei gespeichert wird und danach eine neue Strukturgeberfolie mit der geänderten Struktur hergestellt wird. Diese geänderte Struktur wird dann erneut auf ein mit dem zugehörigen Dekor versehenes Substrat gedruckt und erneut beurteilt. Ggf. werden die Schritte des Optimierens wiederholt. In gleicher Weise kann nach einer Fortbildung der Erfindung auch das Dekor auf dem Substrat optimiert werden, indem das Dekor entweder am Rechner durch Bearbeiten der Datei verändert oder ein ausgedrucktes Dekor neu gescannt wird, und als neue Datei gespeichert wird, um dann auf das Substrat gedruckt zu werden. Das Drucken erfolgt vorzugsweise mit Digitaldruckern, z. B. Laser- oder Tintenstrahldruckern.According to a further advantageous embodiment, the structure can be optimized, in particular to match the decor. The optimization takes place if the structure does not yet meet the requirements by changing the structure, either directly on the computer by editing the file or by editing the printed structure and rescanning it, then saving it as a new file and then producing a new structuring film with the changed structure. This changed structure is then printed again on a substrate provided with the associated decoration and assessed again. If necessary, the optimization steps are repeated. In the same way, according to a further development of the invention, the decoration on the substrate can also be optimized by either changing the decoration on the computer by editing the file or rescanning a printed decoration and saving it as a new file in order to then print it on the substrate to become. Printing is preferably done with digital printers, e.g. B. laser or inkjet printers.

Die Strukturgeberfolie wird durch Drucken hergestellt, vorzugsweise indem ein Struktur gebendes Medium, z. B. Tinte, Pigmente oder Partikel mittels eines Druckers auf eine Folie aufgetragen werden. Das Struktur gebende Medium kann vorzugsweise in einer digitalen Auftragsvorrichtung, z. B. einem 3D-Drucker, einem Laserdrucker oder einem Tintenstrahldrucker verarbeitet werden. Das Medium kann als Feststoff oder in flüssiger Form verarbeitet werden. Bevorzugt wird das Struktur gebende Medium mittels eines Digitaldruckers, insbesondere eines Tintenstrahldruckers, eines Laserdruckers, eines 2-D oder 3-D-Druckers in fester oder flüssiger Form aufgetragen. Das Medium wird dabei auf die Strukturgeberfolie aufgetragen und dort gebunden. Es bildet dort erfindungsgemäß eine Struktur aus, das heißt, dass das Medium nicht nur als Schicht auf der Oberfläche der Strukturgeberfolie, sondern als Erhebung aufgetragen wird, die über die Oberfläche der Folie hinausragt. Im Gegensatz zu einem zweidimensionalen Dekor entsteht damit eine dreidimensionale Struktur, die, je nach Art des verwendeten Mediums, noch trocknen, abbinden oder aushärten muss, z. B. durch Einwirken von Temperatur oder Strahlung wie Laser oder UV-Licht oder Elektronenstrahlung. Es hat sich überraschend herausgestellt, dass die auf die Prägeseite der Strukturgeberfolie aufgetragene Struktur ausreichend fest ist, um die Oberfläche eines Substrats zu prägen.The structuring film is produced by printing, preferably by using a structure-giving medium, e.g. B. ink, pigments or particles can be applied to a film by means of a printer. The structure-giving medium can preferably be used in a digital application device, e.g. B. a 3D printer, a laser printer or an inkjet printer. The medium can be processed as a solid or in liquid form. The structure-giving medium is preferably applied in solid or liquid form by means of a digital printer, in particular an inkjet printer, a laser printer, a 2-D or 3-D printer. The medium is applied to the structuring foil and bound there. According to the invention, it forms a structure there, that is to say that the medium is applied not only as a layer on the surface of the structure generator film, but as an elevation that protrudes beyond the surface of the film. In contrast to a two-dimensional decor, this creates a three-dimensional structure that, depending on the type of medium used, still has to dry, set or harden, e.g. B. by exposure to temperature or radiation such as laser or UV light or electron beams. It has surprisingly been found that the structure applied to the embossing side of the structuring foil is sufficiently strong to emboss the surface of a substrate.

Die Höhe der Struktur kann bevorzugt von 1 µm bis 1000 µm betragen. Sie kann variieren, um ein vorgegebenes Modell detailgenau nachzubilden. Die minimale Höhe ergibt sich durch die minimale Auftragsmenge des Struktur gebenden Mediums, die die Auftragsvorrichtung mindestens verarbeiten kann, die maximale Auftragshöhe ergibt sich durch die maximale Prägung, die in die Oberfläche des Substrats eingebracht werden kann. Es können beispielsweise sich wiederholende Muster oder individuelle Bilder (Silhouetten von Personen, Gegenständen oder Gegenden wie z. B. Stadtsilhouetten), aber auch Nachbildungen von Naturobjekten wie z. B. Holzmaserung, Rindennachbildungen oder Abbildungen von Pflanzen als Struktur auf die Strukturgeberfolie aufgetragen werden.The height of the structure can preferably be from 1 μm to 1000 μm. It can vary in order to reproduce a given model in great detail. The minimum height results from the minimum application amount of the structure-giving medium that the application device can at least process, the maximum application amount results from the maximum embossing that can be made in the surface of the substrate. For example, repeating patterns or individual images (silhouettes of people, objects or areas such as city silhouettes), but also replicas of natural objects such as. B. wood grain, bark replicas or images of plants can be applied as a structure to the structuring foil.

Die Struktur wird in der Regel auf der Grundlage eines digitalen Datensatzes auf die Strukturgeberfolie aufgetragen. Vorteilhaft ist, dass z.B. bei naturgetreuen Nachbildungen von Holzmaserungen der gleiche digitale Datensatz, der für das Herstellen der Struktur genutzt wird, auch eingesetzt werden kann, um eine Dekorfolie, z. B. eine Papierfolie oder eine Kunststofffolie mit einem zweidimensionalen Dekor farblich zu bedrucken. Nach oder vor dem Erzeugen des Dekors wird mit dem identischen Datensatz die korrespondierende Struktur auf die Folie erhöht gedruckt. Auf diese Weise können Substrate einheitlich gestaltet werden, z. B. kann eine Dekorfolie oder ein Dekorpapier auf das Substrat auflaminiert werden, anschließend kann entweder die Dekorfolie oder eine weitere Beschichtung, die auf die Dekorfolie aufgetragen wird, mittels der Strukturgeberfolie mit einer dreidimensionalen Struktur versehen werden.The structure is usually applied to the structure generator film on the basis of a digital data record. It is advantageous that, for example, in the case of lifelike reproductions of wood grains, the same digital data set that is used to produce the structure can also be used to create a decorative film, e.g. B. to print a paper film or a plastic film with a two-dimensional decor in color. After or before the creation of the decoration, the corresponding structure is printed raised on the film with the identical data record. In this way, substrates can be made uniform, e.g. B. a decorative film or a decorative paper can be laminated onto the substrate, then either the decorative film or a further coating that is applied to the decorative film can be provided with a three-dimensional structure by means of the structuring film.

Durch die einfache und preiswerte Herstellung der Strukturgeberfolie mittels einer digitalen Auftragsvorrichtung kann eine Folie zur einmaligen Verwendung oder eine mehrfach verwendbare Folie hergestellt werden. Damit können Muster, Einzelaufträge und Kleinserien wirtschaftlich hergestellt werden.Due to the simple and inexpensive production of the structure generator foil by means of a digital application device, a foil for single use or a reusable foil can be produced. This means that samples, individual orders and small series can be produced economically.

In Abhängigkeit von der Auflösung der digitalen Auftragsvorrichtung kann eine hoch aufgelöste Struktur erzeugt werden. So können Details der Struktur in einer Auflösung von 25 dpi bis 4800 dpi aufgetragen werden. Durch die digitale Auftragsvorrichtung kann das Struktur gebende Medium sehr differenziert und fein verteilt in unterschiedlicher Dicke auf die Druckseite der Strukturgeberfolie aufgetragen werden. Die dreidimensionale Struktur, die auf der Druckseite der Strukturgeberfolie erzeugt wird, kann, bezogen auf die Oberfläche der Druckseite, unterschiedlich dick aufgetragen sein, von ca. 1 µm bis ca. 1000 µm, so dass ausgeprägte reliefartige Strukturen aufgetragen werden können, die meist an der Oberfläche des Substrats taktil wahrnehmbar sind.Depending on the resolution of the digital application device, a high-resolution structure can be generated. In this way, details of the structure can be applied in a resolution of 25 dpi to 4800 dpi. By means of the digital application device, the structure-giving medium can be applied very differently and finely distributed in different thicknesses to the print side of the structure-forming film. The three-dimensional structure that is generated on the print side of the structure generator film can be applied with different thicknesses, based on the surface of the print side, from approx. 1 µm to approx. 1000 µm, so that pronounced relief-like structures can be applied, which are mostly tactile on the surface of the substrate.

Die Strukturgeberfolie kann aus einer Vielzahl von Werkstoffen gewählt werden. Die Strukturgeberfolie kann z. B. aus Metall, insbesondere Aluminium, hergestellt sein. Sie kann auch aus Kunststoff, Papier, Pappe oder einem Verbundwerkstoff hergestellt sein. Sie kann ein- oder mehrschichtig ausgeführt sein. Ist die Strukturgeberfolie aus Kunststoff hergestellt, so weist sie bevorzugt einen oder eine Kombination der nachfolgend aufgeführten Kunststoffe auf: Polyethylen, hochdichtes Polyethylen, Polypropylen, Polyethylenterephtalat, Polyurethan, thermoplastisches Polyurethan, Polyacetat, Polycarbonat, Polyimid, Polystyrol, Polyvinylchlorid oder Polytetrafluorethylen. Zur Herstellung der Strukturgeberfolie können auch Mischungen der vorgenannten Werkstoffe eingesetzt werden, z. B. Mischungen verschiedener Kunststoffe oder Schichten unterschiedlicher Werkstoffe. Optional kann die Strukturgeberfolie auch eine Beschichtung aufweisen, z. B. einen Lack oder einen Primer. Die Beschichtung kann beispielsweise die Haftung des Struktur gebenden Mediums an der Strukturgeberfolie verbessern oder sie kann die Oberflächeneigenschaft der Strukturgeberfolie beeinflussen, z. B. eine matte oder hochglänzende Oberflächen ermöglichen.The structuring film can be selected from a variety of materials. The structuring film can, for. B. made of metal, in particular aluminum. It can also be made of plastic, paper, cardboard or a composite material. It can have one or more layers. If the structuring film is made of plastic, it preferably has one or a combination of the plastics listed below: polyethylene, high-density polyethylene, polypropylene, polyethylene terephthalate, polyurethane, thermoplastic polyurethane, polyacetate, polycarbonate, polyimide, polystyrene, polyvinyl chloride or polytetrafluoroethylene. Mixtures of the aforementioned materials can also be used to produce the structure generator film, e.g. B. Mixtures of different plastics or layers of different materials. Optionally, the structure generator film can also have a coating, e.g. B. a varnish or a primer. The coating can, for example, improve the adhesion of the structure-imparting medium to the structure donor film or it can influence the surface properties of the structure donor film, e.g. B. enable a matt or high-gloss surface.

Mindestens die Druckseite der Strukturgeberfolie kann eine matte oder glänzende bis hochglänzende Oberfläche aufweisen. Entsprechend erzeugt die Druckseite eine matte oder glänzende bzw. hochglänzende Oberfläche auf dem Substrat.At least the print side of the structure generator film can have a matt or glossy to high gloss surface. Accordingly, the print side creates a matt or glossy or high-gloss surface on the substrate.

Wie bereits zuvor beschrieben, wird ein festes oder flüssiges Medium z. B. durch einen 3D-Drucker, einen Laserdrucker oder einen Tintenstrahldrucker auf die Druckseite einer Folie aufgetragen, die so zur Strukturgeberfolie wird. Das Struktur gebende Medium verbindet sich unlösbar mit der Druckseite der Folie, so dass es während des Prägens und auch während des Entfernens der Strukturgeberfolie vom Substrat vollständig an der Druckseite haften bleibt. Dies kann z. B. dadurch geschehen, dass das Struktur gebende Medium durch Trocknen an der Druckseite haftet, indem beispielsweise Wasser oder Lösungsmittel verdunstet. Alternativ kann das Medium aushärten, wenn sich z. B. durch Einwirken von Temperatur und/oder Strahlung Polymere ausbilden oder Feststoffpartikel miteinander und/oder mit der Druckseite der Strukturgeberfolie verbinden, beispielsweise verschweißen, verschmelzen oder verkleben. Typisch wird ein durch einen 3D-Drucker verarbeitetes Medium in Form von Feststoffpartikeln aufgetragen und z. B. durch Laserstrahlung, UV-Strahlung oder andere Strahlung zu einer festen Struktur gesintert, verschmolzen oder verschweißt. Wird das Medium flüssig aufgetragen, so enthält es häufig Monomere oder Oligomere oder Feststoffpartikel, die dann ebenfalls unter Einwirkung von Strahlung polymerisieren, gesintert werden oder verklebt bzw. verschweißt werden. Besteht das flüssige Medium ausschließlich aus einer Substanz, die zur Herstellung der Struktur genutzt wird, entfällt das ansonsten notwendige Entfernen des Lösungsmittels bzw. Wassers. Struktur gebende Medien, entweder in flüssiger Form als Tinten bezeichnet oder als Feststoffpartikel sind an sich bekannt.As already described above, a solid or liquid medium is e.g. B. applied by a 3D printer, a laser printer or an inkjet printer on the print side of a film, which becomes the structure generator film. The structure-giving medium is inextricably linked to the printing side of the film, so that it remains completely adhered to the printing side during the embossing and also during the removal of the structure-giving film from the substrate. This can e.g. B. happen that the structure-giving medium adheres to the print side by drying, for example by evaporating water or solvent. Alternatively, the medium can harden if, for. B. by the action of temperature and / or radiation to form polymers or solid particles with one another and / or with the pressure side of the structure generator film connect, for example weld, fuse or glue. Typically, a medium processed by a 3D printer is applied in the form of solid particles and z. B. sintered, fused or welded to a solid structure by laser radiation, UV radiation or other radiation. If the medium is applied in liquid form, it often contains monomers or oligomers or solid particles, which then polymerize, are sintered or are glued or welded under the action of radiation. If the liquid medium consists exclusively of a substance that is used to produce the structure, the otherwise necessary removal of the solvent or water is not necessary. Structure-giving media, either in liquid form known as inks or as solid particles, are known per se.

Die auf die Druckseite aufgebrachte Struktur, die nach dem Prägen in der Oberfläche des Substrats als Negativ abgebildet wird, kann entweder ein in sich abgeschlossenes Motiv sein, sie kann aber auch ein Motiv mehrfach wiedergeben oder sie kann nur den Teil eines Motivs wiedergeben. Typisch werden z. B. Holzstrukturen oder andere Naturstrukturen wie z. B. Steinstrukturen abgebildet. Es können aber auch jegliche andere Motive wie z. B. Logos, Skylines oder dergleichen hergestellt werden.The structure applied to the print side, which is shown as a negative after the embossing in the surface of the substrate, can either be a self-contained motif, but it can also reproduce a motif several times or it can only reproduce part of a motif. Typically z. B. wood structures or other natural structures such. B. Stone structures shown. However, any other motifs such as B. logos, skylines or the like can be produced.

Vorteilhaft werden unabhängig vom Motiv weitere Informationen auf die Druckseite aufgebracht, z. B. Druckmarken oder andere Informationen, die das Ausrichten der Strukturgeberfolie bezogen auf das Substrat oder eine Presse betreffen, in der die Strukturgeberfolie und das Substrat verpresst werden, um die Struktur auf die Oberfläche des Substrats zu übertragen. Diese Informationen können auch, da sie auf die Oberfläche des Substrats übertragen werden, für spätere Bearbeitungsschritte des Substrats genutzt werden, z. B. um Hinweise zum Aufteilen des Substrats in Einzelteile zu geben. Diese weiteren Informationen können ebenfalls durch die digitale Auftragsvorrichtung aufgebracht werden oder sie können durch andere Auftragsvorrichtungen angebracht werden.Advantageously, further information is applied to the print side regardless of the motif, e.g. B. print marks or other information that relate to the alignment of the structure generator film with respect to the substrate or a press in which the structure generator film and the substrate are pressed in order to transfer the structure to the surface of the substrate. This information can also, since it is transferred to the surface of the substrate, be used for later processing steps of the substrate, e.g. B. to provide information on dividing the substrate into individual parts. This additional information can also be applied by the digital application device or it can be applied by other application devices.

Das Aufbringen einer Struktur auf die Oberfläche eines Substrats umfasst die Schritte des Bereitstellens eines Substrats mit einer Oberfläche und des Bereitstellens einer Strukturgeberfolie mit einer Druckseite, auf die mindestens abschnittsweise ein Struktur gebendes Medium aufgetragen ist, das eine Struktur bildet. Weiter umfasst das Verfahren das Auflegen der Druckseite der Strukturgeberfolie auf die Oberfläche des Substrats und das Pressen von Substrat und Strukturgeberfolie in einer Presse, wobei sich die Struktur, die auf der Druckseite der Strukturgeberfolie aufgetragen ist, in die Oberfläche des Substrats einprägt, da in der Presse glatte, nicht-strukturierte Pressbleche eingesetzt werden. Das auf die Druckseite der Strukturgeberfolie aufgebrachte Struktur gebende Medium kommt also in unmittelbaren Kontakt mit der Oberfläche des Substrats, um dort ein Negativ der auf der Druckseite aufgebrachten Struktur zu erzeugen. Die Oberfläche des Substrats wird erfindungsgemäß reliefartig geprägt und zeigt damit ebenfalls eine Struktur.The application of a structure to the surface of a substrate comprises the steps of providing a substrate with a surface and of providing a structure generator film with a print side, onto which at least in sections a structure is applied giving medium that forms a structure. The method further comprises placing the print side of the structure donor film on the surface of the substrate and pressing the substrate and structure donor film in a press, the structure applied to the print side of the structure donor film being impressed on the surface of the substrate, since in the Press smooth, non-structured press plates are used. The structure-giving medium applied to the printing side of the structure generator film thus comes into direct contact with the surface of the substrate in order to produce a negative of the structure applied to the printing side there. According to the invention, the surface of the substrate is embossed in a relief-like manner and thus likewise shows a structure.

Im einfachsten Fall ist nur der Druck der Presse erforderlich, um die Struktur in die Oberfläche des Substrats einzuprägen. Der Druck beträgt üblicherweise von 10 N/mm2 bis 1000 N/mm2. Meist wird jedoch auch zusätzlich eine erhöhte Temperatur angewandt, damit die Oberfläche des Substrats besser verformbar ist. Die Temperatur beträgt z. B. von 40 °C bis 300 °C, vorzugsweise von 140 °C bis 200 °C.In the simplest case, only the pressure of the press is required to emboss the structure into the surface of the substrate. The pressure is usually from 10 N / mm 2 to 1000 N / mm 2 . In most cases, however, an increased temperature is also used so that the surface of the substrate can be more easily deformed. The temperature is e.g. B. from 40 ° C to 300 ° C, preferably from 140 ° C to 200 ° C.

Der Druck wird durch eine Presse, üblicherweise eine Kurztaktpresse (KT-Presse) oder durch eine kontinuierliche Presse aufgebracht. In der Regel genügt eine Pressdauer von maximal 150 Sekunden, meist genügen 10 Sekunden bis 30 Sekunden, mindestens ist eine Pressdauer von 5 Sekunden ausreichend, um die Struktur auf der Druckseite der Strukturgeberfolie als Negativ, und damit ebenfalls als Struktur auf der Oberfläche des Substrats abzubilden. Die Pressbedingungen werden in Abhängigkeit vom zu prägenden Substrat gewählt. Optimale Pressbedingungen ermittelt der Fachmann mit wenigen orientierenden Versuchen.The pressure is applied by a press, usually a short-cycle press (KT press) or by a continuous press. As a rule, a press duration of a maximum of 150 seconds is sufficient, usually 10 seconds to 30 seconds are sufficient, at least a press duration of 5 seconds is sufficient to depict the structure on the print side of the structure generator film as a negative, and thus also as a structure on the surface of the substrate . The pressing conditions are selected depending on the substrate to be embossed. The expert determines the optimal pressing conditions with a few preliminary experiments.

Als Substrat sind sämtliche Werkstoffe geeignet, die sich durch die Strukturgeberfolie prägen lassen, typisch Holz oder Holzwerkstoffe, Kunststoffe, insbesondere thermoplastische Kunststoffe, Metalle, insbesondere Metallfolien, aber auch keramische Werkstoffe. Holzfaser- oder Spanplatten, Sperrholz, Schichtholz und OSB-Platten zählen zu den Holzwerkstoffen, die im Rahmen der Erfindung als Holzwerkstoffe bezeichnet werden. Die Werkstoffe können auch als Zwischenprodukt, z. B. vor oder während des Trocknens, Pressens oder Aushärtens geprägt werden, wenn sie sich in einem Fertigungszustand befinden, in dem sie noch weich genug sind, geprägt zu werden. Die Werkstoffe können zum Prägen der Oberfläche auch erwärmt oder in anderer Weise temporär erweicht werden, um ein Prägen der Oberfläche zu ermöglichen.All materials that can be embossed by the structuring foil are suitable as the substrate, typically wood or wood-based materials, plastics, in particular thermoplastic plastics, metals, in particular metal foils, but also ceramic materials. Wood fiber or chipboard, plywood, laminated wood and OSB boards are among the wood-based materials that are referred to as wood-based materials in the context of the invention. The materials can also be used as an intermediate product, e.g. B. before or during drying, pressing or curing, if they are in are in a manufacturing state in which they are still soft enough to be embossed. To emboss the surface, the materials can also be heated or temporarily softened in some other way in order to enable the surface to be embossed.

Nach einer vorteilhaften Weiterbildung der Erfindung weist das Substrat eine Oberflächenbeschichtung auf, die durch die Strukturgeberfolie geprägt wird. Diese Oberflächenbeschichtung, die dann die Oberfläche des Substrats bildet, kann bevorzugt aus einem Lack oder einem Kunstharz bestehen. Lack oder Kunstharz können vorteilhaft hochviskos oder getrocknet, aber noch nicht ausgehärtet sein. Auch angelierte Lacke, z. B. UV- oder strahlungshärtende Lacke können auf einfache Weise durch die Strukturgeberfolie geprägt werden, so dass die Oberflächenbeschichtung als Struktur ein exaktes und detailgenaues Negativ der auf die Druckseite der Strukturgeberfolie aufgebrachten Struktur zeigt.According to an advantageous development of the invention, the substrate has a surface coating which is embossed by the structure donor film. This surface coating, which then forms the surface of the substrate, can preferably consist of a lacquer or a synthetic resin. Lacquer or synthetic resin can advantageously be highly viscous or dried, but not yet hardened. Also gelled paints, e.g. B. UV or radiation-curing lacquers can be easily embossed through the structure donor film, so that the surface coating as a structure shows an exact and detailed negative of the structure applied to the print side of the structure donor film.

Typische Kunstharzbeschichtungen können als Oberflächenbeschichtung eines Substrats gut geeignet sein, um mit der erfindungsgemäßen Strukturgeberfolie verpresst zu werden, insbesondere, wenn die Presse mit einer Presstemperatur von ca. 140 °C bis ca. 200 °C betrieben wird. Das Kunstharz wird bevorzugt als vorkondensierte bzw. getrocknete aber noch nicht ausgehärtete Oberflächenbeschichtung z. B. von Holzwerkstoffplatten eingesetzt. Es verflüssigt sich in der Presse bei den genannten Temperaturen. In diesem Zustand kann es durch die Strukturgeberfolie geprägt werden. Im weiteren Verlauf des Pressvorgangs härtet das Kunstharz bei den genannten Temperaturen aus, so dass eine dauerhafte Struktur in die Oberfläche eingeprägt werden kann. Typische Kunstharze sind Melaminharz, Phenolformaldehydharz und Harnstoffharze.Typical synthetic resin coatings can be well suited as a surface coating of a substrate in order to be pressed with the structuring foil according to the invention, in particular if the press is operated at a pressing temperature of approx. 140 ° C to approx. 200 ° C. The synthetic resin is preferably used as a precondensed or dried but not yet cured surface coating, e.g. B. used by wood-based panels. It liquefies in the press at the temperatures mentioned. In this state it can be embossed through the structuring foil. In the further course of the pressing process, the synthetic resin hardens at the temperatures mentioned, so that a permanent structure can be embossed into the surface. Typical synthetic resins are melamine resin, phenol-formaldehyde resin and urea resins.

Aber auch Lacke können ohne Weiteres eingesetzt werden. Häufig verwendete Lacke sind acrylat- oder metacrylatbasierte Lacke, Polyurethanlacke, Epoxidlacke, oder wasserbasierende Lacke. Vorzugsweise werden UV- oder strahlungshärtende Lacke sowie thermisch härtende Lacke verwendet, weil diese Lacke in passgenauer Abstimmung auf die erfindungsgemäße Strukturgeberfolie angeliert (teilweise gehärtet) werden können, so dass nach dem Pressvorgang eine optimale Wiedergabe der Struktur der Strukturgeberfolie in der Lackoberfläche abgebildet ist, z. B. weil der Lack nicht mehr verfließt. Während des Pressvorgangs oder anschließend daran kann der Lack vollständig ausgehärtet werden.But lacquers can also be used without further ado. Frequently used lacquers are acrylate- or methacrylate-based lacquers, polyurethane lacquers, epoxy lacquers, or water-based lacquers. UV- or radiation-curing lacquers and thermosetting lacquers are preferably used because these lacquers can be gelled (partially cured) in a precisely tailored match to the structure donor film according to the invention, so that after the pressing process an optimal reproduction of the structure of the structure donor film is reproduced in the lacquer surface, e.g. . B. because the paint is not more dissipates. The paint can be completely cured during or after the pressing process.

Hat sich herausgestellt, dass ausreichend Nachfrage für eine Struktur gegeben ist, so dass es wirtschaftlich ist, ein Pressblech aus Metall, insbesondere Edelstahl, zum Herstellen der Struktur einzusetzen, wird die Datei mit der ggf. optimierten Struktur erfindungsgemäß zur Herstellung eines Pressblechs eingesetzt und das so strukturierte Pressblech wird an Stelle eines nicht-strukturierten Pressblechs in die Presse eingesetzt. Nun wird zum Herstellen einer größeren Menge eines mit einer Struktur versehenen, dekorierten Substrats lediglich das dekorierte Substrat in die Presse überführt und erfindungsgemäß durch Schließen der Presse geprägt. Die Bedingungen beim Pressen (Zeit, Druck und Temperatur) sind in der Regel dieselben wie beim Prägen der Struktur mittels Strukturgeberfolie.If it has been found that there is sufficient demand for a structure so that it is economical to use a press plate made of metal, in particular stainless steel, to produce the structure, the file with the possibly optimized structure is used according to the invention to produce a press plate and that Press plate structured in this way is used in the press instead of a non-structured press plate. Now, in order to produce a larger quantity of a decorated substrate provided with a structure, only the decorated substrate is transferred into the press and embossed according to the invention by closing the press. The conditions for pressing (time, pressure and temperature) are usually the same as for embossing the structure with a structuring foil.

Details des erfindungsgemäßen Verfahrens werden an Hand eines Ausführungsbeispiels näher erläutert. Es zeigt:
Fig. 1 ein Ablaufschema des erfindungsgemäßen VerfahrensDetails of the method according to the invention are explained in more detail using an exemplary embodiment. It shows:
Fig. 1 a flow chart of the method according to the invention

Wie in Fig. 1 dargestellt, beginnt das erfindungsgemäße Verfahren damit, ein mit einer Struktur versehenes Dekor vorzulegen, z. B. eine Holz- oder Steinoberfläche oder eine künstlich gestaltete Oberfläche. Anschließend werden zunächst das Dekor und dann die Struktur gescannt und in separaten Dateien abgelegt. Die Auflösung kann dabei jeweils von 25 dpi (dots per inch) bis zu 4800 dpi reichen.As in Fig. 1 shown, the inventive method begins to present a decor provided with a structure, for. B. a wood or stone surface or an artificially designed surface. The decor and then the structure are then scanned and stored in separate files. The resolution can range from 25 dpi (dots per inch) to 4800 dpi.

Das Dekor wird nach den in der jeweiligen Datei gespeicherten Daten auf das Substrat, z. B. ein Dekorpapier oder die Oberfläche einer Holzwerkstoffplatte, insbesondere eine Holzwerkstoffplatte mit einer darauf aufgebrachten Kunstharzschicht, gedruckt. Bevorzugt wird hierzu ein Digitaldrucker, z. B. ein Laserdrucker oder ein Tintenstrahldrucker eingesetzt. Parallel dazu wird die in der jeweiligen Datei gespeicherte Struktur auf eine Strukturgeberfolie gedruckt. Die Strukturgeberfolie ist aus einem Kunststoff, hier PET (Polyethylenterephtalat). Sie kann aber aus einer großen Palette von Werkstoffen hergestellt sein, die verschiedene Kunststoffe, Metall, Papier, Pappe oder Verbundwerkstoffe umfasst. Die geeigneten Kunststoffe sind in der allgemeinen Beschreibung aufgezählt. Das Aufbringen der Struktur auf die Strukturgeberfolie erfolgt mittels eines digitalen Druckers, z. B. eines Laser- oder Tintenstrahldruckers, der Strukturen in einer Schichtstärke von 1 µm bis 1000 µm auf die PET-Folie aufdruckt. Die Tinte oder ein anderes mittels des Druckers aufgebrachtes Medium haftet fest auf der Folie und ist von einer Dichte, die geeignet ist, ein Substrat mit darauf aufgebrachtem Dekor zu prägen.The decoration is applied to the substrate according to the data stored in the respective file, e.g. B. a decorative paper or the surface of a wood-based panel, in particular a wood-based panel with a synthetic resin layer applied to it, printed. A digital printer, e.g. B. a laser printer or an inkjet printer is used. At the same time, the structure saved in the respective file is printed on a structuring foil. The structuring film is made of a plastic, here PET (polyethylene terephthalate). However, it can be made from a wide range of materials, including various plastics, metal, paper, or cardboard Includes composite materials. Suitable plastics are listed in the general description. The structure is applied to the structure generator film by means of a digital printer, e.g. B. a laser or inkjet printer that prints structures in a layer thickness of 1 µm to 1000 µm on the PET film. The ink or another medium applied by means of the printer adheres firmly to the film and has a density that is suitable for embossing a substrate with a decoration applied to it.

Anschließend wird die Struktur mittels der Strukturgeberfolie auf das mit dem Dekor versehene Substrat geprägt. Dazu wird ein Pressgutstapel aus dem Substrat, das mit einem Dekor versehen ist, und der Strukturgeberfolie in die Presse eingebracht. Das Substrat ist im vorliegenden Fall eine 8 mm Faserplatte und das Dekor ist als kunstharzgetränktes Dekorpapier auf einer Oberseite der Faserplatte aufgebracht. Der Pressgutstapel wird zwischen glatten, nicht-strukturierten Pressblechen gepresst. Das Prägen erfolgt bevorzugt in einer Kurztaktpresse (KT-Presse). Im einfachsten Fall ist nur der Druck der Presse erforderlich, um die Struktur in die Oberfläche des Substrats einzuprägen. Der Druck beträgt üblicherweise von 10 N/mm2 bis 1000 N/mm2. Vorliegend wird jedoch auch zusätzlich eine erhöhte Temperatur angewandt, damit die Oberfläche des Substrats besser verformbar ist. Die Temperatur liegt meist in einem Bereich von 40 °C bis 300 °C, vorzugsweise von 140 °C bis 200 °C, vorliegend bei 160 °C.The structure is then embossed onto the substrate provided with the decoration by means of the structure generator film. For this purpose, a stack of pressed material consisting of the substrate, which is provided with a decoration, and the structure generator film is introduced into the press. In the present case, the substrate is an 8 mm fibreboard and the decor is applied as a synthetic resin-impregnated decor paper on a top side of the fibreboard. The stack of pressed material is pressed between smooth, non-structured press plates. The embossing is preferably carried out in a short-cycle press (KT press). In the simplest case, only the pressure of the press is required to emboss the structure into the surface of the substrate. The pressure is usually from 10 N / mm 2 to 1000 N / mm 2 . In the present case, however, an increased temperature is also used so that the surface of the substrate can be more easily deformed. The temperature is usually in a range from 40.degree. C. to 300.degree. C., preferably from 140.degree. C. to 200.degree. C., in the present case 160.degree.

Wenn das Dekor und die Struktur -wie im vorliegenden Ausführungsbeispiel- aufeinander abgestimmt sind, dann ist nach einem ersten Pressen der Struktur auf das Dekor zu prüfen, ob die Struktur und das Dekor optimal aufeinander abgestimmt sind. Zudem ist zu prüfen, ob die Struktur, die ursprünglich vom Original abgenommen wurde, in der gepressten Ausführung ebenfalls optimal ist oder ob noch Optimierungsbedarf besteht, z. B. in der Farbgebung, in der Präzision der Abstimmung auf das Dekor oder der Anordnung und Ausführung der Struktur hinsichtlich der Tiefe der Prägung. Gleiches gilt für das Dekor. Selbst wenn das Dekor als Vorlage gut geeignet schien, ist in der fertig gepressten Ausführung zu prüfen, ob weiterer Optimierungsbedarf besteht, z. B. in der Anpassung der Farbgebung, der Verbesserung von Schattierungen oder der Konturenschärfe.If the decor and the structure - as in the present exemplary embodiment - are matched to one another, then after a first pressing of the structure onto the decor it is to be checked whether the structure and the decor are optimally matched to one another. In addition, it must be checked whether the structure that was originally removed from the original is also optimal in the pressed version or whether there is still a need for optimization, e.g. B. in the coloring, in the precision of the coordination with the decor or the arrangement and execution of the structure with regard to the depth of the embossing. The same goes for the decor. Even if the decor seemed well suited as a template, the finished pressed version should be checked to see whether there is any need for further optimization, e.g. B. in the adaptation of the color scheme, the improvement of shading or the sharpness of the contours.

Nachdem dieser Optimierungsbedarf ermittelt ist, werden die Dateien für die Struktur und das Dekor überarbeitet und entsprechend des Optimierungsbedarfs angepasst, wenn die Änderungen unmittelbar mittels Rechner an der Datei vorgenommen werden können. Wenn nicht, wird ein Ausdruck der Struktur und/oder des Dekors ausgedruckt, bearbeitet und erneut gescannt, so dass jeweils eine geänderte Datei vorliegt. Die Struktur wird gemäß der angepassten Datei erneut auf eine Strukturgeberfolie ausgedruckt und wie vorstehend beschrieben auf ein Substrat mit Dekor gepresst. Ist das Dekor ebenfalls angepasst worden, wird zuvor auch das angepasste Dekor auf das Substrat gedruckt, so dass überprüft werden kann, ob die geänderte Version der Struktur und ggf. des Dekors zueinander passen. Dieser Vorgang kann so oft wiederholt werden, bis das Ergebnis zufriedenstellend optimiert ist. Es liegt auf der Hand, dass das Herstellen einer Strukturgeberfolie schnell und unkompliziert und im Verhältnis selbst zu kleinen Probe-Pressblechen von ca. 50 cm x 50 cm sehr viel preiswerter ist.After this need for optimization has been determined, the files for the structure and the decor are revised and adapted according to the need for optimization if the changes can be made directly to the file using a computer. If not, a printout of the structure and / or the decor is printed out, edited and scanned again so that a modified file is available in each case. The structure is printed out again on a structure generator film according to the adapted file and pressed onto a substrate with decoration as described above. If the decor has also been adapted, the adapted decor is also printed on the substrate beforehand so that it can be checked whether the changed version of the structure and, if applicable, the decor match one another. This process can be repeated until the result is satisfactorily optimized. It is obvious that the production of a structuring foil is quick and uncomplicated and much cheaper in relation to even small test press plates of approx. 50 cm x 50 cm.

Probedrucke und kleine Einzelaufträge können allein unter Nutzung der Strukturgeberfolie hergestellt werden. Größere Mengen von mit einer Struktur versehenen Substraten können dagegen wirtschaftlicher hergestellt werden, indem ein strukturiertes Pressblech eingesetzt wird. Erfindungsgemäß wird die optimierte Datei zum Herstellen eines strukturierten Pressblechs genutzt, so dass auch große Mengen eines mit einer Struktur versehenen Substrats wirtschaftlich hergestellt werden können.Test prints and small individual orders can be produced using the structuring foil alone. On the other hand, larger quantities of substrates provided with a structure can be produced more economically by using a structured press plate. According to the invention, the optimized file is used to produce a structured press sheet so that large quantities of a substrate provided with a structure can also be produced economically.

Auf diese Weise werden nicht nur die Kosten der Herstellung strukturierter Substrate reduziert. Erfindungsgemäß werden strukturierte Pressbleche nur dann hergestellt, wenn es tatsächlich wirtschaftlich ist, während bisher spekuliert werden musste, ob die Herstellung eines bestimmten strukturierten Pressbleches sich wirtschaftlich lohnt. Gleichzeitig wird die Bevorratung von strukturierten Pressblechen wesentlich einfacher, weil nur noch solche Pressbleche gefertigt werden, die tatsächlich zur Herstellung großer Mengen von strukturierten Substraten erforderlich sind.This not only reduces the costs of producing structured substrates. According to the invention, structured press plates are only produced if it is actually economical, whereas previously it had to be speculated whether the production of a certain structured press plate is economically viable. At the same time, stocking structured press plates is much easier because only those press plates are produced that are actually required for the production of large quantities of structured substrates.

Claims (9)

  1. A method for creating structures on a substrate, having the steps of:
    providing a decoration which is provided with a structure,
    scanning the decoration and the structure and storing the decoration and structure in separate files, and subsequently creating structures on a substrate in two steps, wherein, in a first step,
    the decoration is printed onto a substrate,
    the three-dimensional structure is printed onto the printing side of a structure-providing film, wherein a structure is applied as an elevation which protrudes beyond the surface of the structure-providing film,
    the structure is embossed by means of the printing side of the structure-providing film onto a substrate provided with the decoration,
    if necessary, the structure is optimized and the structure is printed again onto a structure-providing film and the structure is embossed by means of the printing side of the structure-providing film onto a substrate provided with the decoration and wherein, in a second step,
    the structure which is optimized if necessary is transferred to a pressing plate by using the file having the structure which is optimized if necessary, in order to create a pressing plate, and wherein, after the thus structured pressing plate is inserted into a press, the structure which is optimized if necessary is embossed from the pressing plate onto the decorated substrate by closing the press.
  2. The method according to claim 1, characterized in that the structure on the printing side of the structure-providing film has a height of 1 µm up to 1000 µm with respect to the printing side.
  3. The method according to claim 1 or 2, characterized in that the structure has a resolution of 25 dpi up to 4800 dpi.
  4. The method according to at least one of the preceding claims, characterized in that the structure-providing film is created from metal, plastic, paper, cardboard or a composite.
  5. The method according to claim 4, characterized in that a structure-providing film is used, which has aluminum, polyethylene, high-density polyethylene, polypropylene, polyethylene terephthalate, polyurethane, thermoplastic polyurethane, polyacetate, polycarbonate, polyimide, polystyrene, polyvinyl chloride or polytetrafluoroethylene or a combination of these materials.
  6. The method according to at least one of the preceding claims, characterized in that the structure-providing film has a mat, a glossy or a high-gloss printing side.
  7. The method according to at least one of the preceding claims, characterized in that a stainless-steel plate is used as a pressing plate.
  8. The method according to at least one of the preceding claims, characterized in that the optimization is carried out multiple times in that the structure is effected by editing the file or by processing and rescanning the printed-out structure, and then stored as a new file.
  9. The method according to at least one of the preceding claims, characterized in that the decoration is optimized.
EP18162046.9A 2018-03-15 2018-03-15 Method for creating structures on a substrate Active EP3539792B1 (en)

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PL18162046T PL3539792T3 (en) 2018-03-15 2018-03-15 Method for creating structures on a substrate
EP18162046.9A EP3539792B1 (en) 2018-03-15 2018-03-15 Method for creating structures on a substrate
PT18162046T PT3539792T (en) 2018-03-15 2018-03-15 Method for creating structures on a substrate
ES18162046T ES2894945T3 (en) 2018-03-15 2018-03-15 Procedure for producing structures on a substrate

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP18162046.9A EP3539792B1 (en) 2018-03-15 2018-03-15 Method for creating structures on a substrate

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EP3539792B1 true EP3539792B1 (en) 2021-08-04

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Publication number Priority date Publication date Assignee Title
EP4271573A1 (en) * 2020-12-29 2023-11-08 Giorgio Macor Method providing a workpiece with a three-dimensionally textured surface coating
IT202100031211A1 (en) * 2021-12-13 2023-06-13 Gruppo Mastrotto S P A METHOD FOR THE SERIAL REPRODUCTION OF RELIEF DESIGNS ON FLEXIBLE LAMINAR MATERIALS
IT202200015618A1 (en) * 2022-07-25 2024-01-25 Giorgio Macor Method for generating a decoration that can be peeled off on command and product thus obtained.

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GB0620712D0 (en) * 2006-10-18 2006-11-29 Flotek Internat Ltd Method of embssing a substrate
US7947139B2 (en) * 2007-12-14 2011-05-24 Kings Mountain International, Inc. Systems and methods for creating textured laminates
ES2391421T3 (en) 2008-10-27 2012-11-26 Flooring Technologies Ltd. Procedure for finishing a support plate, in particular a wood or wood composite plate
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
RU2642767C2 (en) * 2012-07-17 2018-01-25 Сералок Инновейшн Аб Surface with changed digital impression with register

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PT3539792T (en) 2021-10-26
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PL3539792T3 (en) 2022-01-03

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