EP4134242B1 - Method and device for applying a decoration and a surface structure to a substrate - Google Patents

Description

The invention relates to a method for applying a decoration and a surface structure to a carrier material and a device suitable for this purpose. According to the method, a carrier material or at least one decorative paper is printed with a decoration and a file for the surface structure is created from the digital image data of the decoration. Furthermore, at least one layer of a resin is applied to the printed carrier material or to at least one overlay, the distribution of the resin being specified by the file for the surface structure and thus depending on the printed decoration. The at least one resin layer is then pressed with the carrier material using a structured press sheet or the at least one overlay, the at least one decorative paper and a carrier material are pressed with a structured press sheet. In both cases, the structure of the pressed sheet is specified by the surface structure file and is therefore also dependent on the printed decor. With the method according to the invention, a surface structure is formed on the carrier material, which is synchronous with the applied decoration.

The use of wood-based panels or wood-plastic composite panels (WPC = wood plastic composites) in the furniture industry, as floor coverings, table tops or for cladding walls and ceilings requires processing or refining of the surface of the wood-based panels or wood-plastic composite panels. Usually, in the case of the areas of application mentioned Wood-based panels coated with an impregnated decorative paper. To increase wear resistance, an overlay is applied to the decorative paper. Thin paper is used as an overlay, which has typically been soaked with a melamine resin. In addition, abrasion-resistant particles, such as corundum particles, can be mixed into the resin of the overlay in order to increase the abrasion resistance of the wood-based panels or wood-plastic panels.

Alternatively, the wood-based panels or wood-plastic panels can also be printed directly with a decor. Several liquid thermosetting resin layers (usually melamine resins) are then usually applied to the decor applied by direct printing, which in turn can contain abrasion-resistant particles to increase wear resistance.

When producing wood-based panels or wood-plastic panels with a melamine resin coating, an essential quality feature is the pleasing surface structure. This should not only be synchronous with the decor, but also be as accurate a replication as possible of the underlying template from nature or another product in terms of the structural depths of the structure of the decor. What is most important is that the replica has an optical and tactile impression that is as true to the original as possible. It is therefore desirable that the embossed structure is coordinated with the printed decor and thus a decor-synchronous structure or a synchronous pore is formed.

Until now, wood reproductions have often been the focus of end-user interest. In order to achieve the most lifelike results possible, the wooden materials were provided with simple pore structures during production. The structure depth was usually below 100 µm, often even below 50 µm. For special applications such as table tops in offices, even flat structures (deck structure) were prescribed.

With the advent of digital printing, a wide variety of material reproductions have now become of interest to end consumers. Among other things, stone, fantasy or intarsia decors have come into focus. Due to the new decorative requirements and new products (elastic floor coverings), more and more deep structures are now required. These are often large-scale impressions such as: B. for imitation tiles, heavily structured woods or inlays are commonplace.

This creates a problem for products coated with melamine resin in the floor covering sector from the prior art, since these structures sometimes go well beyond a structure depth of 100 µm. On the one hand, these laminate products are made almost exclusively with HDF (fiberboard with high gross density) with gross densities over 800, sometimes even over 900 kg/m ³ . These cannot be structured without considerable effort (very high pressure), which is not possible on many older design short-cycle presses (KT presses). These can press with a maximum of 50 kg/cm ² , which is not sufficient for structures with a structure depth greater than 200 µm. On the other hand, the top side is either worked with an impregnated structure (resinized overlay paper and printed and resinated decorative paper) or with direct printing on a color primer. These layers can crack if there is deep structuring and then lead to laminate products that are of poor quality.

In addition, it has been shown that when deeply structured sheets, ie pressed sheets with structure depths around 600 µm, are used, presses with pressing pressures above 50 kg/cm ² and extended pressing times (> 20 sec) initially achieve a compression of the structure and thus a corresponding structure is also impressed. However, this compression and thus the resulting structuring is largely lost again after pressing due to the so-called "spring back" effect. The compressed materials expand again and the compression becomes less dense or compact.

• Die Strukturierung mit Strukturtiefen größer 200µm ist äußerst schwierig ;
• Es müssen unter Umständen Investitionen getätigt werden, um Pressen mit höheren Pressdrücken anzuschaffen;
• Eine einwandfreie Qualität kann nicht garantiert werden.

There are therefore decisive disadvantages:

• Structuring with structure depths greater than 200µm is extremely difficult;
• Investments may have to be made to purchase presses with higher pressing pressures;
• Perfect quality cannot be guaranteed.

From the prior art, for example, the die is used to apply surface structures EP 3 738 787 A1 known. Although this describes the application of powdered resin layers to printed wood-based panels, as already stated, no structures with a depth greater than 200 µm can be formed by applying these resin layers.

The EP 2 913 199 B1 deals with the construction of haptic structures using 3D printing. This process is extremely time-consuming and cannot be used to produce large quantities in a short period of time. The method of choice for Fast production of printed wood materials or printed wood-plastic materials are manufacturing processes with at least one KT press. However, a 3D printing process cannot be used sensibly or efficiently in such a situation. The process is therefore uneconomical and is only suitable for small quantities or for producing prototypes.

• Eine Lackschichten muss innerhalb kürzester Zeit getrocknet/angehärtet werden, um ein Verlaufen der Tröpfchen zu verhindern;
• Die Eigenschaften der verwendeten Lacke müssen genau gesteuert und bekannt sein (Viskosität, Tixotropie);
• Lack ist ein sehr preisintensiver Rohstoff, was die Wirtschaftlichkeit in der Produktion verringert;
• Das Verfahren kann nicht in die üblichen bestehenden Produktionsprozesse eingegliedert werden. Das Aufbringen der Lackstruktur kann, ähnlich dem Aufbringen einer Struktur durch 3D-Druck, nicht in einem Herstellungsverfahren mit mindestens einer KT-Presse erfolgen. Die Produktionsdauer wird dadurch verlängert, was die Wirtschaftlichkeit des Verfahrens enorm mindert.

The DE 10 2009 044 802 A1 discloses a method in which a surface structure is built up by applying paint droplets of different sizes. In order to build deep structures, several layers of paint droplets must be applied one after the other, whereby each layer must first be at least partially dried/hardened before another is applied. The process is therefore able to create structures with a depth between 1 µm and 3 mm, which can also be designed as synchronous pores. However, the process has several disadvantages:

• A layer of paint must be dried/hardened within a very short time to prevent the droplets from running;
• The properties of the paints used must be precisely controlled and known (viscosity, tixotropy);
• Paint is a very expensive raw material, which reduces the cost-effectiveness of production;
• The process cannot be integrated into the usual existing production processes. Similar to applying a structure using 3D printing, the application of the paint structure cannot be carried out in a manufacturing process with at least one KT press. This extends the production time, which enormously reduces the economic efficiency of the process.

US 2014/0023832 A1 discloses a method according to the preamble of claim 1 in the alternative wherein the resin layer is applied to an overlay. EP 2 036 741 A2 discloses a method according to the preamble of claim 1 in the alternative, wherein the resin layer is applied to a directly printed support.

The present invention is therefore based on the object of eliminating the disadvantages of the prior art and of providing a method with which decor-synchronous structures of a variety of decors in a cycle line with at least one means for pressing onto a wood material or a wood Plastic material can be applied.

For this purpose, the invention provides a method for applying a decoration and a surface structure to a carrier material, according to claim 1.

The present invention further comprises a device for applying a decoration and a surface structure to a carrier material using the method according to the invention, according to claim 14.

Detailed description

According to the invention, a carrier material or a carrier material, at least one decorative paper and at least one overlay are provided.

In a process step of the method according to the invention, the carrier material or at least one decorative paper is printed with a decoration. The decor is preferably in digital form. Alternatively, an analog decor must be converted into a digital decor. Possibilities for this, such as photographing with a digital camera, scanning with a color scanner or scanning with a hyperspectral scanner are known from the prior art.

The decor is printed onto the carrier material or at least one decorative paper using a direct printing process. In particular, gravure printing and digital printing processes are used as direct printing processes. The gravure printing process is a printing technique in which the elements to be depicted are present as depressions in a printing form that is colored before printing. The printing ink is located primarily in the depressions and is transferred to the object to be printed, such as a carrier material, due to the contact pressure of the printing form and adhesion forces. When using indirect gravure printing, several printing rollers are used.

In a preferred embodiment of the present invention, the decoration is printed onto the carrier material or at least one decorative paper using digital printing processes. With digital printing, the printed image (decor) is transferred directly from a computer to a printing machine, such as a laser printer or inkjet printer. This eliminates the need to use a static printing form. Decorative printing is carried out using the inkjet principle in a single pass, which spans the entire width of the top side to be printed, with the carrier material or at least one decorative paper being moved under the printer. However, it is also possible for the carrier material to be printed or the at least one decorative paper to be stopped under the printer and for it to pass over the surface at least once during printing. What is particularly advantageous when using a digital printing process for printing the carrier material or the at least one decorative paper is that the decoration is already in digital form.

According to the present invention, the carrier material is selected from the group comprising wood-based panels, in particular medium-density fiber (MDF) panels, high-density fiber (HDF) boards, particle boards, coarse particle boards (OSB), plywood boards and wood-plastic boards (WPC).

In one embodiment of the present invention, a primer is applied to the carrier material before printing or before applying at least one decorative paper. For this purpose, the carrier material can, for example, be provided with a primer layer made of a resin and/or a lacquer. For priming, an aqueous resin solution and/or a radiation-curable filler can be applied to the side of the carrier material to be printed or to the side facing the decorative paper. For example, aqueous formaldehyde-containing resin solutions such as melamine-formaldehyde resins, urea-formaldehyde resin or melamine-urea-formaldehyde resin can be used as primers. It is also possible to prime the carrier material in advance with UV filler and/or ESH filler and then cure the primer layer accordingly. Of course, the primers can also contain pigments.

In one embodiment, abrasion-resistant particles and/or glass beads can also be applied to the primer. Abrasion-resistant particles can be selected from a group comprising corundum (aluminum oxides), boron carbides, silicon dioxides, silicon carbides, silanized corundum particles. By applying abrasion-resistant particles and/or glass balls, the wear resistance of a carrier material provided with a decoration and a structure can be increased.

Furthermore, the primer can have at least one additive and/or at least one additive. Suitable additives are selected from the group comprising hardeners, wetting agents (surfactants or mixtures thereof) and release agents. Suitable additives are selected from the group comprising conductive substances and cellulose. The conductive substances can be selected from the group containing soot, carbon fibers, metal powder and nanoparticles, in particular carbon nanotubes.

In a further embodiment of the present invention, a primer layer is applied to the primer, preferably as a one-time application with subsequent drying. The primer layer is particularly useful in the case of a subsequent gravure printing process (with rollers), whereas it is not absolutely necessary when using a digital printing process. Polyurethane-based compounds are preferably used as primers.

According to the invention, a file for the surface structure is created from the digital image data of the decoration. This is done using appropriate computer software. The file for the surface structure contains the digital data of the surface structure of the decor and thus a structure depth assigned to each pixel of the decor.

If the decor is already available digitally, in one embodiment the decor data for the individual color channels can be separated from the digital data of the decor using software such as PhotoShop, Paint or PaintShop Pro. The digital data from the color channels in turn contain information about the surface structure. The color channel, e.g. B. that contains information about the "wood grain", i.e. dark colors, would then indicate a reduced or no resin application. Each color channel therefore contains information about the structural depth of a specific image point in the decor. A pore in the wood grain is then formed as a depression on the surface of the final product. The digital data of the color channels contains information about the surface structure and can therefore serve as digital data of the surface structure. In one embodiment of the present invention, the file for the surface structure therefore contains the digital data of the surface structure of the decoration in the form of the digital data of the color channels.

In one embodiment of the present invention, the digital image data of the decor is created by scanning an analog decor template. In one embodiment, the file for the surface structure can be generated directly from the digital data from the scanner. Scanners are known from the prior art that combine 2D data or data from different lighting situations and use this to calculate digital data for the surface structure of the scanned decoration. METIS Systems S.r.l., for example, provides suitable scanners for this purpose. and the company Cruse Spezialmaschinen GmbH. In this embodiment, the file for the surface structure therefore contains the digital data of the surface structure of the decoration in the form of the digital data of the surface structure, as provided by a suitable scanner.

Alternatively, the scanned digital data can also be separated into the decor data for the individual color channels using software such as PhotoShop, Paint or PaintShop Pro. This procedure has already been described in detail.

In a subsequent process step, at least one layer of resin is applied to the printed carrier material or to at least one overlay, the distribution of the resin being specified by the digital data of the file for the surface structure and thus depending on the printed decoration.

According to the invention, the determination in which areas of the carrier material or the overlay and which amount of resin per area is applied is determined by the digital data of the file for the surface structure. Since the file for the surface structure contains the surface structure of the decor in digital form and thus a structure depth assigned to each pixel of the decor, the amount of application of the at least one resin layer is precisely tailored to the decor. In areas where elevations are later to be present in the carrier material provided with the decoration, a larger amount of resin is applied per area than in areas with flatter structures or without structure.

In one embodiment, multiple layers of resin are applied to the printed substrate or overlay. Between 2 and 6 layers of resin, preferably between 2 and 5 layers of resin, particularly preferably between 2 and 4 layers of resin can be applied. The application of several layers may be necessary, for example, if order quantities cannot be achieved in one run. Multiple layers of resin can also be applied only in areas where a larger amount of resin is to be applied per area compared to surrounding areas.

After the at least one resin layer has been applied, in one embodiment it can be dried or fixed. This prevents the resin layer from running. If several layers of resin are applied, this can be allowed to dry after each layer has been applied.

The resin of the at least one resin layer can be applied as a powdery resin and/or as a liquid resin. If resin powder is used instead of liquid resin, there is no need to dry on at least one and every additional resin layer. This reduces system costs, exhaust air problems and space requirements in the production facility. Suitable powdered resins have a particle size between 20 and 100 µm, preferably between 40 and 89 µm. A powdered resin can be applied, for example, via a digital printer. The control of the digital printer, i.e. the control of the order quantity depending on the location, is done using the digital data of the surface structure file. The resolution of the order quantity then corresponds to the resolution of the digital printer. The resolution of the application quantity describes how small adjacent areas with different application quantities of resin can be. After applying a layer of a powdery resin, in one embodiment it can be fixed, for example, by an infrared emitter (IR emitter).

If a liquid resin is used for the at least one resin layer, it preferably has a solids content of over 70% by weight. The solids content influences the viscosity of the liquid resin, with a solids content of over 70% by weight preventing the resin from running after application. In one embodiment of the invention, the liquid resin can be additionally heated to further increase the viscosity of the resin. By heating the resin, it is partially but not completely polymerized, so that further crosslinking or polymerization is possible at a later processing time. A liquid resin can be applied, for example, through nozzles. The nozzles are controlled, i.e. the application quantity is controlled depending on the location, using the digital data from the surface structure file. The resolution of the application quantity then corresponds to the resolution of the nozzles used. After applying a liquid resin layer, it can be dried using a circulating air dryer/IR lamp.

Suitable resins are selected from the group comprising melamine-formaldehyde, phenol, melamine-urea-formaldehyde and urea-formaldehyde resins.

The resin can also have at least one additive and/or at least one additive. The same groups of additives and additives prove to be useful as already described for the primer.

According to the invention, the total amount applied of the at least one resin is preferably between 100 and 500 g/cm ² of resin. As already described, the appropriate amounts of resin can be applied all at once or in several layers.

If an overlay is used, it can be impregnated before the at least one resin layer is applied. Liquid resins are suitable for impregnation, preferably having a solids content of less than 70% by weight, particularly preferably less than 68% by weight. exhibit. Suitable resins for impregnation are selected from the group consisting of melamine-formaldehyde, phenol, melamine-urea-formaldehyde and urea-formaldehyde resins. The resin can also have at least one additive and/or at least one additive. The same groups of additives and additives prove to be useful as already described for the primer. Furthermore, additional abrasion-resistant particles and/or glass beads can be applied to the not yet dried resin during impregnation. Abrasion-resistant particles can be selected from a group comprising corundum (aluminum oxides), boron carbides, silicon dioxides, silicon carbides, silanized corundum particles. By applying abrasion-resistant particles and/or glass balls, the wear resistance of a carrier material provided with a decoration and a structure can be increased.

In a further method step, the at least one resin layer with the carrier material is pressed with a structured press sheet or the at least one overlay, the at least one decorative paper and a carrier material are pressed with a structured press sheet. The structure of the pressed sheet is specified by the digital data in the surface structure file.

According to the invention, a structured pressed sheet is used, the structure of which is specified by the digital data of the file for the surface structure. Since the file for the surface structure contains the surface structure of the decor in digital form and thus a structure depth assigned to each pixel of the decor, the structure of the pressed sheet for the decor can be specified precisely using this file. The structure can, for example, be milled or etched out of the pressed sheet; alternatively, it is also possible to apply additional layers of material to the pressed sheet. To form a joint structure in a tile decoration, for example, trapezoids or similar bodies can be applied to the pressed sheet to form the desired structure. Of course, all possible geometries can be realized using appropriately produced pressed sheets, which correspond to structures of ornaments, lettering, branches, pores, simulated signs of use or other decorative structures. In principle, any technique familiar to a person skilled in the art can be used to provide the pressed sheet with the structure specified by the digital data in the file for the surface structure.

When pressed, the pressed sheet then structures the layer structure, with part of the structure height resulting from the application of at least one resin layer. This creates a structure on the carrier material, which can also be used on a larger scale viewing distance, e.g. standing upright on a floor covering, is perceived. The structuring of the carrier material is created in the at least one resin layer and extends into the carrier material. In this way, structure depths can be formed which are determined by the application amount of the at least one resin layer and the structure of the pressed sheet. When forming the structures on the carrier material according to the present invention, approximately 50% of the structuring occurs through the structuring of the carrier material and 50% through the structuring of the at least one resin layer. According to the invention, a surface structure with a structure depth greater than 200 µm, preferably greater than 300 µm, particularly preferably greater than 400 µm is formed on the carrier material at least in sections. Structures with such a structural depth could not previously be produced using the prior art processes or could only be produced at great expense (3D printing, application of lacquer layers). Furthermore, it was not possible to create such structures within a production line using short-cycle presses (KT presses). The present method eliminates these disadvantages and enables integration into existing manufacturing processes, which increases cost efficiency. In addition, integration into existing cycle lines with KT presses enables high production cycles, which brings with it an enormous economic advantage.

1. a) Trägermaterial - optional mindestens eine Grundierung - mindestens eine Harzschicht
2. b) Trägermaterial - optional mindestens eine Grundierung - mit Dekor bedrucktes Dekorpapier - Overlay mit mindestens einer Harzschicht

According to the invention, the layer structure that is pressed can have the following structure:

1. a) Carrier material - optionally at least one primer - at least one resin layer
2. b) Carrier material - optionally at least one primer - decorative paper printed with decor - overlay with at least one resin layer

In the layer structure according to point a), the decor was printed directly onto the carrier material after applying an optional primer.

According to the invention, the surface structure that is formed on the carrier material is synchronous with the applied decoration. Before pressing, according to the invention, the carrier material and the pressed sheet or the carrier material, the decorative paper and the overlay are positioned relative to one another in such a way that the decor and structure of the pressed sheet or decor, the overlay with the at least one resin layer and the pressed sheet are congruent with one another, that is to say they are synchronous. The exact positioning can be done, for example, with the help of markings on the carrier material, decorative paper, overlay and press sheet using a camera system.

If an overlay is used, it preferably has markings on the edge. For positioning purposes, in addition to the distance between the markings in the longitudinal direction, the distance between the markings in the transverse direction is also advantageously determined.

In a preferred embodiment of the present invention, the pressing of the at least one resin layer with the carrier material is carried out with a press sheet or the pressing of the at least one overlay, the at least one decorative paper and a carrier material with a press sheet is carried out in a KT press (short-cycle press). This has the advantage that processing of carrier materials using the method according to the invention can be carried out at high speeds and therefore extremely efficiently and economically.

In a further embodiment of the invention, a backing, for example consisting of several resin layers or a backing paper, can be applied to the underside of the carrier material. This ensures that the tensile forces on the carrier material caused by the layers applied to the decorative side and the underside during pressing cancel each other out. The amount of resin applied to the underside corresponds approximately to the amount applied to the decorative side, but without the addition of abrasion-resistant particles and/or glass balls.

• optionale mindestens eine Auftragsvorrichtung zum Auftragen von mindestens einer Grundierungsschicht;
• optionale mindestens eine Auftragsvorrichtung zum Auftragen von mindestens einer Primerschicht;
• mindestens eine Druckvorrichtung;
• mindestens ein Kamerasystem;
• ein Mittel zum Erstellen einer Datei für die Oberflächenstruktur aus den digitalen Bilddaten des Dekors;
• mindestens eine Auftragsvorrichtung zum Auftragen der mindestens einen Harzschicht;
• optional eine Auftragsvorrichtung zum Aufbringen von Korund und/oder Glaskugeln;
• optional eine Vorrichtung zum Antrocknen einer aufgetragenen Harzschicht;
• ein Mittel zum Verpressen der mindestens einen Harzschicht mit dem Trägermaterial oder des Overlays und des Dekorpapiers mit einem Trägermaterial mit einem strukturierten Pressblech;
• wobei das strukturierte Pressblech eine Struktur aufweist, die durch die digitalen Daten der Datei für die Oberflächenstruktur vorgegeben ist.

Furthermore, the present invention comprises a device for applying a decoration and a surface structure to a carrier material using the method according to the invention

• optional at least one application device for applying at least one primer layer;
• optional at least one application device for applying at least one primer layer;
• at least one printing device;
• at least one camera system;
• a means for creating a surface texture file from the digital image data of the decor;
• at least one application device for applying the at least one resin layer;
• optionally an application device for applying corundum and/or glass beads;
• optionally a device for drying an applied resin layer;
• a means for pressing the at least one resin layer with the carrier material or the overlay and the decorative paper with a carrier material with a structured press sheet;
• wherein the structured pressed sheet has a structure that is specified by the digital data of the surface structure file.

The features of the method according to the invention also apply to the device according to the invention and vice versa.

The application device for applying at least one primer layer and optionally at least one primer layer can be a roller mill.

The device comprises at least one printing device, suitable printing devices are printing devices for the gravure printing and digital printing processes. Laser printers or inkjet printers are preferred for digital printing.

Furthermore, the device comprises a camera system, with the help of which the structured pressed sheet and the carrier material or the structured pressed sheet, the decorative paper, the overlay and the carrier material can be positioned relative to one another by markings in such a way that the carrier material, the pressed sheet and possibly the overlay and that Decorative paper is congruent in terms of structure and decor.

A suitable means of creating a file for the surface structure, containing the digital data of the surface structure of the decoration, from the digital image data of the decoration, is a computing unit, which can be a PC, a tablet or another terminal device on which suitable computer software is installed .

The at least one application device for applying the at least one resin layer can, as already described, be a digital printer or a device with nozzles, the application device having a computing unit or being connected to a computing unit which has computer software which determines the amount of resin applied as a function controlled from location.

In one embodiment, the device has a device for drying an applied resin layer. Suitable devices are, for example, infrared emitters (IR emitters) or circulating air dryers.

Optionally, the device also has an application device for applying corundum and/or glass beads. Suitable application devices for this are, for example, spreading machines. Spreading devices essentially consist of a supply hopper, a rotating, structured roller and a scraper. The amount of abrasion-resistant material applied is determined by the rotation speed of the roller. The spreading device preferably comprises a spiked roller.

Furthermore, the device comprises a means for pressing the at least one resin layer with the carrier material or the overlay and the decorative paper with a carrier material with a structured press sheet. This means is particularly preferred: a short-cycle press (KT press). According to the invention, the structured press sheet used in the pressing device has a structure that is specified by the digital data of the file for the surface structure.

The method according to the invention and the device according to the invention make it possible to work on existing production lines without investments. There is only marginal intervention in existing and established manufacturing processes. In addition, raw materials that are already available in production can be used. The surface structure is essentially made possible by the application of at least one resin layer and the use of suitably structured pressed sheets. Suitable resins can be obtained inexpensively, which increases the economic efficiency of the process.

Figur 1

stellt eine Ausführungsform des Verfahrens in der erfindungsgemäßen Vorrichtung dar.

The invention is explained in more detail below using 1 figure and 2 exemplary embodiments.

Figure 1

represents an embodiment of the method in the device according to the invention.

Figure 1 shows a layer structure in the process according to the invention during pressing. An overlay 40 with a resin layer 20, the application amount of which varies, is arranged on the carrier element 10 provided with decorative paper. Above the resin layer 20, the structured pressed sheet 30 is shown, its structure 31 is aligned congruently with the decor printed on the carrier element. Since both the application amount of the resin layer 20 and the structure 31 of the pressed sheet are coordinated with the decor, the resin layer 20 and the structure 31 of the pressed sheet are also coordinated with one another. So that surface structures of different depths can be formed during pressing. The surface structures of the finished pressed layer structure are then synchronous with the decor of the layer structure.

Example 1

An 8 mm HDF board, digitally printed on the top with a tile decoration (with a printed cement joint), which was provided with a melamine resin coating (approx. 20 g solid resin/m ² ) to protect the print, was introduced into a production line. First, approximately 60 g of liquid melamine resin per m ² with a solids content of approximately 60% by weight were applied using a roller applicator. The melamine resin contained the usual auxiliary materials such as hardeners and wetting agents. Approximately 12 g of corundum/m ² (F200) and 18 g of glass beads/m ² were successively scattered into the resin using scattering machines. The glass spheres had a grain size range of 80 - 110 µm. The melamine resin was flashed off over a distance of 10 m.

30 g of liquid melamine resin per m ² with a solids content of approximately 65% by weight were then applied using four additional roller applicators. A melamine resin application in the same amount was also applied to the back of the HDF board as a counterbalance. Hot air/circulating air drying was carried out after each application.

Three HDF panels were prepared in this way. A thickened melamine resin with a solids content of 70% by weight was then applied to two HDF boards in a final application using a nozzle strip. On one of the HDF panels, an amount of 150 g/m ² was applied in the tile printing areas, but not in the cement joint printing areas. On the second HDF board, an amount of 285 g/m ² was applied in the tile printing areas, but not in the cement joint printing areas. The information for controlling the nozzles came from the digital printing data for decorative printing. The resin was then dried using an IR radiator so that the moisture content of the resin was approx. 8% by weight. All three HDF panels were then pressed in a short-cycle press at a pressing temperature of approx. 200°C, 50 kg/cm ² pressing pressure and 20 seconds of pressing time, with the positioning of the panels to be pressed to the structured press sheet being helped of a camera system so that the plate and press sheet were aligned with each other.

In the areas where the cement joints in the decor are located, the chrome-plated pressed sheet had trapezoidal elevations that protruded approximately 500 µm above the sheet surface. These trapezoidal elevations (longitudinal and transverse) formed the cement joint in print on the pressed sheet. In the places where there were no elevations, the pressed sheet had a deckle structure. The transparency of the pressing showed no defects. After pressing, the structural depth/height difference between the cement joint and the tile pressure was determined on the panels. sample Application quantity of thickened melamine resin in g/m ² Structure depth in µm 1 0 195 2 150 305 3 285 410

Embodiment 2 - Overlay

In a first step, an overlay (paper weight: 25 g/m ² ) was impregnated on an impregnation channel with a melamine resin with a solids content of approximately 65% by weight. The overlay should later be pressed together with a tile decoration in a short-cycle press. The overlay had reading marks for a scanner at regular intervals in the edge area. The resin application was approximately 150 g liquid/m ² . Corundum was sprinkled into the not yet dried resin in an amount of approx. 20 g/m ² using a spreading device. The grain size according to FEPA standard was F200. The impregnate was then dried back in a float dryer to a residual moisture content of approx. 15% by weight.

Three overlays were prepared in this way. In another order, a thickened melamine resin with a solids content of 70% by weight was applied to two overlays using a nozzle bar. An amount of 150 g/m ² was applied to one overlay and an amount of 285 g/m ² to another overlay. This was done in the areas of the overlay that would later be on the tile print areas, but not in the cement grout print areas. The information for controlling the nozzles came from the digital printing data for decorative printing. To The markings on the edge of the overlay were used for precise positioning. In addition to the distance between the markings in the longitudinal direction, this was also determined in the transverse direction. The resin was then dried using another float dryer so that the moisture content of the resin was approximately 6% by weight. The overlays were then separated into sheets using a clipper.

The three overlays were then placed on HDF panels with a decorative impregnate (tile decor), which was also marked at regular intervals in the edge area. The HDF panels served as the carrier material. The exact positioning of the overlay on the decorative impregnate and the positioning of the structure in the press were carried out using a camera system. To ensure tension symmetry, there was a counterweight in the form of an impregnate on the underside of the HDF panels. A press plate with a tile structure was installed in the KT press for pressing. The structure was pressed in the KT press at a temperature of approximately 200°C, a pressure of approximately 40 kg/cm ² and a pressing time of approximately 15 seconds. After pressing the three different overlays, the structure depth was determined. sample Application quantity of thickened melamine resin in g/m ² Structure depth in µm 1 0 150 2 150 230 3 280 330

Reference symbol list

10

Carrier material

20

resin layer

30

Pressed sheet metal

31

Structure of the pressed sheet

40

Overlay

Claims (14)

1. Method for applying a decoration and a surface structure to a carrier material (10), comprising the following steps:

   providing a carrier material (10) or a carrier material (10), at least one decorative paper and at least one overlay (40);

   printing the carrier material (10) or the at least one decorative paper with a decoration;

   producing a file for the surface structure, containing the digital data of the surface structure of the decoration, from the digital image data of the decoration;

   applying at least one layer of resin (20) to the printed carrier material (10) or to at least one overlay (40), the distribution of the resin being dictated by the digital data of the file for the surface structure and thus being dependent on the imprinted decoration;

   pressing the at least one resin layer (20) with the carrier material (10) using a structured press platen (30), or pressing a carrier material (10), the at least one decorative paper and the at least one overlay (40) bearing the at least one resin layer (20) using a structured press platen (30), the structure of the press platen (30) being dictated by the digital data of the file for the surface structure and thus being dependent on the printed decoration;

   where a surface structure is formed on the carrier material (10) that is synchronous to the applied decoration;

   where a part of the structure height of the surface structure results from the application of the at least one resin layer;

   characterized in that

   the structuring of the carrier material (10) is generated in the at least one resin layer and extends into the carrier material (10); and

   in that, at least in portions, a surface structure having a structure depth of more than 200 µm is formed.
2. Method according to Claim 1, characterized in that, at least in portions, a surface structure having a structure depth of more than 300 µm, particularly preferably more than 400 µm, is formed.
3. Method according to either of the preceding claims, characterized in that multiple layers of resin (20) are applied to the printed carrier material (10) or to the overlay (40).
4. Method according to any of the preceding claims, characterized in that pulverulent and/or liquid resin is applied.
5. Method according to any of the preceding claims, characterized in that the resin is selected from the group containing melamine-formaldehyde resins, phenolic resins, melamine-urea-formaldehyde resins and urea-formaldehyde resins.
6. Method according to any of the preceding claims, characterized in that the liquid resin is applied with a solids content of more than 70%.
7. Method according to any of the preceding claims, characterized in that the resin comprises at least one additive and/or adjuvants.
8. Method according to Claim 7, characterized in that the at least one additive is selected from the group containing curing agent, wetting agent and release agent and/or the at least one adjuvant is selected from the group containing conductive substances and cellulose.
9. Method according to any of the preceding claims, characterized in that between 100 and 500 g/cm² of resin are applied.
10. Method according to any of the preceding claims, characterized in that an undercoat is applied to the carrier material (10).
11. Method according to any of the preceding claims, characterized in that after the application of a layer of resin it is incipiently dried or set.
12. Method according to any of the preceding claims, characterized in that the pressing of the at least one resin layer with the carrier material (10) using a press platen (30) or the pressing of the at least one overlay (40), the at least one decorative paper and a carrier material (10) using a press platen (30) is carried out in an SC press (short-cycle press).
13. Method according to any of the preceding claims, characterized in that the carrier material (10) is selected from the group containing wood-based material boards, more particularly medium-density fibreboard (MDF), high-density fibreboard (HDF), chipboard, oriented-strand board (OSB), plywood boards and wood-plastic composite (WPC) boards.
14. Apparatus for applying a decoration and a surface structure to a carrier material (10) by a method according to any of Claims 1 to 13, comprising

    optionally at least one application apparatus for applying at least one undercoat layer;

    optionally at least one application apparatus for applying at least one primer layer;

    at least one printing apparatus;

    at least one camera system enabling positioning of the structured press platen and the carrier material or the structured press platen, the decorative paper, the overlay and the carrier material relative to one another;

    a means for producing a file for the surface structure from the digital image data of the decoration;

    at least one application apparatus for applying the at least one resin layer (20), the application apparatus comprising a computing unit or being connected to a computing unit which comprises computer software which controls the amount of resin applied as a function of location;

    optionally an application apparatus for applying corundum and/or glass beads;

    optionally an apparatus for incipiently drying an applied resin layer (20);

    a means for pressing the at least one resin layer (20) with the carrier material (10) or for pressing the overlay (40) and the decorative paper with a carrier material (10) using a structured press platen (30);

    wherein the structured press platen (30) has a structure dictated by the digital data of the file for the surface structure.

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