A process for achieving decor on a surface element

ES 2 215 775 T3

DESCRIPTION

Procedure to obtain a decoration on a surface element.

The present invention relates to a method for obtaining a decoration on a surface element, in which a decorative top layer has a considerably improved matching of decoration between adjacent surface elements.

Currently, in many areas the coating of products with thermoset sheet material is common. They are mainly used when the requirements for resistance to abrasion are high, and when resistance against different chemical agents and humidity is also desired. As examples of such products there may be mentioned floors, floor covering, table tops, work tops and wall panels.

Thermoset sheet material most often consists of a number of base sheets with a decoration sheet positioned closest to the surface. If desired, the decoration sheet can be provided with a pattern. Common patterns usually visualize different kinds of wood or mineral, such as marble and granite.

A common pattern on floor elements is the rod pattern in which two or more rows of rods made of, for example, wood are simulated.

Traditional thermoset sheet material fabrication includes a number of steps that will result in a random match tolerance of up to ± 5mm, which is considered high. The steps included in the manufacture of a laminate floor are: printing the decoration on α-cellulose paper, impregnating the decorative paper with melamine-formaldehyde resin, drying the decorative paper, laminating the decorative paper under heat and pressure together with papers. treated in a similar way, apply the decorative sheet material on a support and finally saw and mill the support into the desired format. All these stages in the manufacture will produce a change of format in the decorative paper. Therefore, it will be practically impossible to obtain a desired pattern match between the elements of a decoration, without producing large amounts of residual sheet material. Thermoset sheet material is a fairly expensive part of a laminate floor.

WO-A-98/26936 describes a method for transferring an image to a coating for a laminating process that includes the step of transferring the digitally saved or photographed image in an electrostatic laser printing process. GB-A-2324982 describes a method of screen printing a pattern on a surface of a wood composite material which includes the step of adjusting the color balance of the scanned or photographed image for reproduction.

In the present invention, it has been possible to overcome the above-mentioned problems and a surface element with a decorative surface has been obtained in which the decorative pattern is coincident between different surface elements. The invention relates to a method for obtaining a decoration on surface elements comprising a decorative top layer and a support core. The invention is characterized in that:

i) A segmentation pattern is selected, the segmentation comprising at least two decorative segments in each surface element. As noted above, the shape of the surface element is hereby selected from the group: triangular, square, rectangular, heptagonal, pentagonal and octagonal, while the shape of the segments is selected from the group triangular, square, rectangular, heptagonal, pentagonal, octagonal, circular, elliptical, altered, and irregular.

ii) Next, a segment decoration is selected for each segment. The segment decoration is selected from the group: simulated and digitized representation of different kinds of wood, minerals and stone, different kinds of fabrics, graphic designs and fantasy-based decoration.

iii) Each selection is made in a terminal, where the selections come from a database and the selection is viewed through the terminal.

Preferably, the decoration is obtained by the digitization of a real archetype or the partial or complete creation on a digital medium. The digitized decoration is preferably saved digitally for use as a control function and as an original, together with control programs and selection parameters, when the decoration is printed.

The dimensions of the surface to be covered by the surface elements are entered appropriately in the terminal and the support programs calculate an installation pattern. The installation pattern calculation is also appropriately used to print an assembly instruction. To display the selection, the installation pattern calculation is used to print a miniature copy of the calculated installation with the selected pattern and decoration. The dimensions of the surface to be covered by the surface elements are entered appropriately in the terminal and those support programs additionally calculate the pattern of segmentation and decoration that match between the surface elements.

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Preferably, the selections are also used, in conjunction with supporting programs, to control additional steps in the manufacturing process selected from the group: identification marking, placement marking, packaging, lacquering, surface etching, warehousing and shipping logistics.

An algorithm is suitably used to guide the placement of the decoration segments and the segmentation pattern so that a decorative segment of a surface element can continue onto an attached surface element. The control program is appropriately used, together with the decoration data and the selection parameters, to apply a matching identification on the surface elements.

It is also possible to fabricate a larger designed surface with larger decorative segments than a surface element, using the process as described below:

i) A selected main decoration is introduced through a terminal, proceeding the selected decoration from a group consisting of: a digitized archetype through a scanner or digital camera and a digitized decoration from a database.

ii) Next, the dimensions of the surface to be covered by the surface elements and the desired dimension of the decoration on the terminal are entered. The support programs are used to calculate the segmentation of the main decoration that will cover more than one surface element.

iii) Finally, the result of the selections and calculations is displayed through the terminal.

The digitized main decoration is digitally saved to be used as a control function and as an original, along with the control programs and selection parameters, when the decoration is printed.

To enhance the decorative effect of some decorations, it is possible to select a surrounding decoration. A decorative effect is also appropriately selected at the boundary between the main decoration and the surrounding decoration, the group selection being made: dimming, sharp edge, sharp edge with shadow effect, jagged edge, jagged edge with shadow and surrounding ornament of other decoration .

Preferably, the surrounding decoration is treated as follows;

i) A segmentation pattern is selected for the surrounding decoration. The segmentation comprising at least two decorative segments in each surface element. As noted above, the shape of the surface element is preferably selected from the group: triangular, square, rectangular, heptagonal, pentagonal, and octagonal. The shape of the surface elements with surrounding decoration and the shape of the surface elements is naturally selected so that they can be joined together. The shape of the segments is selected from the group triangular, square, rectangular, heptagonal, pentagonal, octagonal, circular, elliptical, altered and irregular.

ii) Next, a segment decoration is selected for each segment. The segment decoration is selected from the group: simulated and digitized representation of different kinds of wood, minerals and stone, different kinds of fabrics, graphic designs and fantasy-based decoration.

iii) Each selection is made in a terminal in which the selections come from a database. The selection is displayed through the terminal.

A decorative effect is appropriately selected on the boundary between the main decoration and the surrounding decoration. The selection is mainly made from the group: dimming, sharp edge, sharp edge with shadow effect, jagged edge, jagged edge with shadow and surrounding embellishment of other decoration. This selection is also made in the terminal.

The dimensions of the surface to be covered by the surface elements are entered appropriately in the terminal and the support programs calculate an installation pattern. The installation pattern calculation is preferably used to print an assembly instruction. The installation pattern calculation is used, according to one embodiment of the invention, to print a miniature copy of the calculated installation with the selected decoration and pattern. This impression can serve as a design evaluation copy before making manufacturing decisions.

The dimensions of the surface to be covered by the surface elements are entered in the terminal. Support programs additionally calculate the pattern of segmentation and decoration that matches between the surface elements. The selections are preferably used in conjunction with support programs to control additional steps in the manufacturing process, selected from the group: identification marking, placement marking, packaging, lacquering, surface etching, warehousing, and shipping logistics. Preferably, an algorithm is used to guide the placement of the decoration segments and the segmentation pattern so that a decorative segment of a surface element can continue onto an attached surface element. Next, the control program is preferably used, together with the decoration data and the selection parameters, to apply a match identification on the surface elements.

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The surface elements can be used as ceiling, wall or floor panels. Surface elements are properly manufactured using the following procedure:

i) A support core is manufactured in a desired format and provided with an upper side and a lower side.

ii) Next, the upper side of the support core is provided with a decoration, for example by printing. The decoration is placed after a predetermined fixing point on the support core.

iii) The upper side of the support core is then provided with a wear protective layer, at least partially translucent, for example by a spray coating, a roll coating, a curtain coating and a dip coating or by providing it with one or more sheets of αcellulose impregnated with lacquer or thermosetting resin.

The decoration is appropriately obtained by digitizing a real archetype or by being fully or partially created on a digital medium. The digitized decoration is digitally saved to be used as an original and as a control function, along with possible control programs, when the decoration is printed.

Accordingly, the decoration can be obtained by making a high resolution or selected resolution digital image of the desired decoration. This can appropriately be done by means of a scanner or digital camera. The most common decoration will naturally be of different kinds of wood and minerals such as marble, as these will likely continue to be a preferred surface decoration in homes and in public settings. However, it is possible to render anything that is visible. The digitized version of the decoration is then edited to fit the size of the support core. It is also possible to rearrange the decoration in different ways, changing the color tones, the contrast, dividing the decoration into smaller segments and adding other decorative elements. It is also possible to create the entire decoration on a computer equipped for graphic design. It is possible to create a simulated decoration so lifelike that even a professional will have great trouble visually distinguishing it from the original material. This makes it possible, for example, to make floor panels with an almost perfect illusion of a rare kind of wood, such as ebony, rosewood and thus keeping the trees under threat of extinction.

Digital decoration is used in conjunction with orientation programs to control a printer. The printer can be of an electrostatic type or ink jet type printer. In most cases, yellow, magenta, cyan, and black will suffice for the printing process, but in some cases it may be advantageous to add white. Some colors are difficult to obtain using yellow, magenta, cyan, black, and white, so light magenta and light cyan can be added. It is also possible to add so-called spot colors when it is difficult to achieve specific shades of colors or when only certain parts of the color spectrum with intermixed shadows are desired. The resolution required is highly dependent on the decoration to be simulated, but resolutions of 10 - 1500 dots per inch (dpi) is the practical range in which most decorations will be printed. Under normal conditions, a resolution of 300 - 800 dpi is sufficient when creating very complex decorative pattern simulations and yet a result is achieved that is visually very difficult to distinguish from the archetype without detailed and thorough examination.

Digitally saved decoration can also be used in conjunction with support programs when other operations and procedures are performed in the manufacturing process. Such steps in operation may include procedures such as identification marking, packaging, lacquering, surface etching, warehousing and shipping logistics, as well as assembly instructions.

It is advantageous to manufacture the support core in the desired end-user format and to provide it with appropriate edges for bonding prior to applying the wear and decorative layer, as this radically reduces the amount of waste. Decoration match tolerances will also be further improved by this procedure.

The main part of the supporting core is suitably constituted by a particle board or a fiber board. However, it is possible to manufacture the core consisting at least partially of a polymer such as for example polyurethane or a polyolefin, such as polyethylene, poplipopropylene or polybutene. A polymer composite core can be obtained by injection molding or pressure molding and can be shaped by plastic molding and thus does not require any abrasive treatment. A polymer composite core can also contain, except for the polymer, a filler in the form of a particle or fiber of organic or inorganic material which, apart from the use of a material that reduces costs, will also be used to modify the mechanical characteristics of the core. As an example of such suitable fillers there may be mentioned: cellulose or wood particles, straw, starch, glass, lime, talc, stone dust and sand. Mechanical characteristics that can be changed are for example viscosity, thermal expansion coefficient, elasticity, density, fire resistance, moisture absorption capacity, acoustic properties, thermal conductivity, resistance to wear and tear. flexure, as well as softening temperature.

The upper surface, that is, the surface to be provided with the decoration, is appropriately surface treated before printing. A surface treatment of this type will incorporate at least one of the stages,

ES 2 215 775 T3 application of a primer coat and sanding. It is also possible to provide the surface with a structure that matches the decoration to be applied.

The translucent wear layer is suitably constituted by an electron beam or UV curing lacquer, such as an acrylic, epoxy or maleimide lacquer. The wear layer is properly applied in several stages with an intermediate cure, where the latter is a full cure while the former are only partial. By this means, it will be possible to obtain flat and thick layers. The wear layer suitably includes hard particles with a mean particle size in the range of 50 nm - 150 µm. First, larger particles, in the range of 10 - 150 μm, preferably in the range of 30 μιη - 150 μm, are used to obtain abrasion resistance, while smaller particles, in the range of 50 nm - 30 µm, preferably 50 nm - 10 µm, are used to obtain scratch resistance. Here, the smaller particles are used closer to the surface while the larger ones are distributed in the wear layer. The hard particles are suitably constituted of silicon carbide, silicon oxide, α-aluminum oxide and the like. By this, the resistance to abrasion is substantially increased. For example, particles in the range of 30mm 150mm can be sprayed into the still wet lacquer so that, at least partially, they become embedded in a finished wear layer. Therefore, it is suitable to apply the wear layer in several stages with intermediate spray stations where the particles are added to the surface. Thereafter, the wear layer can be cured. It is also possible to mix smaller particles, usually particles smaller than 30 μm with a standard lacquer. Larger particles can be added if a gelling agent or the like is present. A lacquer with smaller particles is suitably used as top coat coatings, closer to the top surface. The scratch resistance can be improved by spraying the very small particles in the range of 50 nm - 1000 nm in the uppermost layer of the lacquer. These, called nano-particles, can also be mixed with lacquer, with which it is applied in a thin layer with a high content of particles. These nanoparticles can also be made up of diamond, in addition to silicon carbide, silicon oxide, α-aluminum oxide.

According to one embodiment of the invention, the translucent wear layer is made up of one or more sheets of α-cellulose that are impregnated with melamine-formadehyde resin. These sheets are bonded to the core under heat and pressure, so the resin cures. In this embodiment, it is also possible to add hard particles with a mean particle size in the range of 50 nm - 150 µm. First of all, larger particles are used, in the range of 10 μm - 150 μm, preferably 30 μιη - 150 μm to obtain an abrasion resistance, while the smaller particles, in the range of 50 nm - 30 μm , preferably 50 nm - 10 µm, are used to obtain scratch resistance. Therefore, the smaller particles are used on or very close to the upper surface, while the larger particles can be distributed in the wear layer. Also here, the particles are advantageously constituted of silicon carbide, silicon oxide, α-aluminum oxide, diamond or the like, of which diamond is used as particles smaller than 1 µm for cost reasons. The α-cellulose sheets are here appropriately compressed with the rest of the surface element in a continuous band press with two steel bands. The pressure in the press suitably ranges between 5-100 bar, preferably 20-80 bar. The temperature suitably ranges in the range of 140-200 ° C, preferably 160-180 ° C. It is also possible to use a batch process in which a number of surface elements can be simultaneously compressed in a so-called multi-aperture press. Then the pressure is normally 20-150 bar, preferably 70-120 bar, while the temperature is suitably 120-180 ° C, preferably 140-160 ° C.

The decoration on the surface elements is suitably constituted by a number of decoration segments with intermediate limits, which limits, on at least two opposite edges, coincide with adjacent, provided surface elements.

It is also desirable to provide the surface elements with a surface structure intended to increase the realism of the decoration of the surface elements. This is suitably obtained by placing at least one structured surface matrix, which forms at least one surface structure segment on a corresponding decoration segment or in a number of decoration segments on the decorated surface of the surface element in connection with the application of the wear layer. This matrix is ​​compressed towards the wear layer so that it will receive a surface with a structure that improves the realism of the decoration.

When more complex patterns are simulated, such as a block wood V pattern or other decoration with two or more oriented and divergent decorations, the use of at least two structured matrices that form a frame segment each is suitable. The structured segments are here independent of each other from a structural point of view. The surface structure segments are intended to at least partially but preferably completely coincide with the corresponding decoration segments of the decoration. The structural surface segments are precisely positioned on the decoration side of the surface element in connection with the application of the wear layer, and are compressed therein, whereby the wear layer is endowed with a surface structure in which the The orientation of the structure corresponds to the different directions in the decoration.

One or more dies preferably form the surface of one or more rollers. The surface element is then passed between the roller or rollers and the counter rollers, with the decoration side facing the structured rollers. The structured rollers are continuously or discontinuously compressed towards the decoration surface of the surface element.

ES 2 215 775 T3

The rollers containing two or more dies are suitably provided with a circumference adapted to the frequency of repetition of the change of direction in the decoration.

It is also possible to apply the structural matrices on the surface of a compression band. The surface element is then passed between the compression band and a compression counter-band under continuous or discontinuous pressure between the structured compression band and the compression counter-band.

According to an alternative method, it is possible to have one or more dies forming the structural surface of one or more static molds, which are momentarily compressed towards the decorative side of the surface element.

According to an embodiment of the invention, in particular characteristic decoration segments such as delimitation lines between simulated slabs, bars, blocks or the like and also knots, cracks, fissures and veins that are visually simulated in the decoration are saved as digital data. Said data is used to guide automated compression or engraving tools when said characteristic decorative segments are provided with an appropriate surface structure, and when said compression or engraving tool is synchronized through the predetermined attachment point on the surface element.

The process described in the present application to manufacture surface elements is very advantageous from a logistical point of view since the number of stages is radically reduced when a new decoration is obtained. According to the present invention, it is possible to use digitally created or saved data to directly print the decoration on a surface element using an ink jet printer or a photo-static printer. The so-called set-up time will therefore be very short, whereby even very special customer requirements can be met at a reasonable cost. According to the present invention, it is possible to manufacture, for example, a world map in a very large format, which is spread over a large number of surface elements without any deviation of interruption in the correspondence of decoration, mainly at the same cost as surface elements. produced raw. Since the decoration can be digitally manipulated to the point of being applied to the surface of the core, adjustment times will be practically non-existent while, at the same time, a high degree of automation can be achieved. It is also possible to automatically equip surface elements with identification and orientation marks that would make the installation of complex decoration much easier, such as world maps in the example above. Up to this point this had been impossible.

The surface elements manufactured as described above are suitably used as a floor covering material, in which the requirements on resistance to abrasion, scratches and stability are high. According to the present invention, it is possible to use surface elements, such as decorative ceiling and wall material. However, in the latter cases it will not be necessary to apply thick wear layer coatings as direct abrasion rarely occurs on such surfaces.

The invention is further described in connection with an accompanying figure, exemplary embodiments and schematic descriptions of the method showing various embodiments of the invention.

Accordingly, the figure shows parts of a surface element 1 including an upper decorative layer 2, joining edges 3, a lower side 4 and a supporting core 5. The process starts by manufacturing a support core 5 with a desired format and joining edges 3. The support core 5 is further provided with an upper side 1 'suitable for printing and a lower side 4. The upper side 1 'of the support core 5 is then provided with a decoration 2' by printing, using an ink jet printer. The decoration 2 'is oriented after a predetermined fixing point on the support core 5. The upper side 1 'of the support core 5 is then provided with a translucent wear protective layer 2 "by curtain coating. The support core 5 is constituted by a panel of particles or a panel of fibers. The 2 "translucent wear layer consists of a UV curing acrylic lacquer that is applied in several stages with an intermediate cure, of which the last is a full cure while the former are only a partial cure. The wear layer 2 "also includes hard α-aluminum oxide particles with a mean particle size in the range of 0.5 µ / im 150 µ / m.

A structured surface matrix is ​​placed and compressed towards the decoration side of the surface element 1 before the final curing of the acrylic lacquer, whereby the surface of the 2 "wear layer receives a 2" surface structure that improves the realism of decoration 2 '.

It is also possible to use two or more structured surface matrices, each one forming a structured segment, between which the structure is independent, which will make it possible to simulate the surface structure of, for example, a wooden block decoration with a V pattern. .

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Process scheme 1

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A polymer and load based support core is manufactured in the desired format and is provided with an upper side, a lower side and edges provided with joining elements, such as a male and a female. The upper side of the support core is then sanded after which a primer coat is applied. Next, a decoration is applied on the upper side by means of a digital photo-static 5-color printer. Colors are magenta, yellow, cyan, white, and black. The decoration is placed from a predetermined fixing point in the form of a corner of the support core, while the direction of the decoration is aligned with the long side edge starting from the same corner.

The basis for decoration is saved as digital data. This digital data has been obtained by digitizing a number of wood grain patterns with a digital camera. From the digital woodgrain images, a number of rectangular blocks with a fixed width, but variable length, are selected and separated. The width of the rectangular blocks is selected so that three block widths correspond to the width of a support core. Next, the digital image of the wood blocks is classified after the color and wood grain pattern, so that a number of groups is obtained. The groups are: light wood with uniform grain, dark wood with uniform grain, light wood with knots and fissures, dark wood with knots and fissures, light wood with interlocking grain and finally dark wood with interlocking grain. Each group contains five different block simulations. An algorithm is entered into a computer, used to guide the printing operation, so that the simulated wooden blocks are digitally placed in three longitudinal rows and mixed so that two similar wooden blocks are never placed side by side. of the other. The algorithm will also guide the position of the latitudinal boundaries between the simulated blocks of wood so that they are misaligned with more than one block width between adjacent rows. It will also guide the latitudinal position of the boundaries so that it lines up with the shorter edges of the support core or gets misaligned by more than one block width. Another printer, also guided with the computer, is used to print a corresponding operation number on the lower lateral edges of the short sides. Therefore, the decoration will continue to be longitudinal on the surface elements and a perfect match will be obtained when the surface elements are placed in numerical order.

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Next, a base coat of UV curing acrylic lacquer is applied by means of a roller. Particles with a mean particle size in the range of 150 µm are sprayed into the still wet base layer, whereby the UV curing acrylic lacquer is applied by spray coating. The two layers of lacquer are partially cured using UV light so the viscosity of the lacquer increases. Next, a top coat of UV curing acrylic lacquer with an additive in the form of hard particles with an average size of 2 µm is applied with a roller. Next, hard particles with an average size of 100 nm are sprayed on top of the upper wet layer, whereby the lacquer is partially cured with UV light so that the viscosity increases. The still soft lacquer is then endowed with a structure in the form of small, narrow, elongated recesses that simulate the pores of wood. This will increase the realism of the decoration. This is achieved by alternating between two different structured rollers per row of simulated wooden blocks. The structure of the rollers even simulates wood grain and wood grain interlocking respectively. The rollers are alternately pressed towards the lacquered surface as it passes. The placement of the rollers is oriented through the digitally stored data used to print the decoration as well as the fixing point used.

According to an alternative embodiment, it is possible to use one or more static molds with a surface structure that is momentarily pressed towards the decoration side.

Especially characteristic decoration segments, such as boundary lines between slabs, bars, blocks or the like and also knots, cracks, fissures and veins that are visually simulated in the decoration, are appropriately stored as digital data. These data are obtained by treating selected parts of the simulated blocks of wood so that the guidance data is obtained. Then, said data is used to guide an automated robot equipped with an engraving tool or a pressure mold that provides the surface of the lacquer with a structure that matches said characteristic decoration segments. Operation is also synchronized through the predetermined attachment point on the support core.

The lacquer is then fully cured with UV light to the desired strength, whereby the finished surface elements can be examined visually or by a computer-supported digital camera. The surface elements are then packaged in batches and endowed with identification marks.

The above process will make it possible to have a completely customized manufacturing in which even very small quantities can be produced with the same efficiency as bulk manufacturing. Although only one decoration has been described in connection with the above process scheme, it is clear to one skilled in the art that a decoration is very easily changed in the process. All important manufacturing steps such as printing, structuring, inspection, packaging and identification marks can be controlled and monitored with centralized processing data. This will logistically make it possible to manufacture a decoration designed to suit the client. Such a process is exemplified as follows:

The customer uses a database via the Internet or from a local reseller. It is also possible to use a database for another operator. The database contains samples and / or low-resolution copies of a wide variety of standard decorations that can be combined after predetermined parameters.

For example, the parameters may refer to a single surface element when, for example, a V pattern, a diamond pattern, and a block pattern may be the choices of decoration segmentation. Here, it will be possible to select a set of different simulations to fill randomly, or by selected parameters, the segments, for example, marble, birch and mahogany. The customer can also add an ornament from their own design that is digitized and processed, preferably automatically, in a desired format and resolution.

The parameters may alternatively include decoration segments that require the spacing of various surface elements, for example, a world map. The parameters may further include here the attenuation of the larger design to a surrounding decoration, a surrounding frame or other decoration, etc.

Customers enter the measurements of the surface to be covered by the surface elements. The customer then makes their choice from the database and is able to view their selection as a complete surface, either on screen or by printing. The visualization program used is also used appropriately to calculate the installation pattern and present the installation instructions with the identification numbers on the surface elements and where to cut the elements to make a perfect fit. The surface elements can also be provided with adjustment lines that can be removed on the decorative side making it easier to adjust the decoration between adjacent rows. The customer or supplier can thus confirm their order via email in which the pattern and decoration are reduced to a code sequence and the order can be entered directly into the computer that guides the manufacturing process as shown. described above. Customer and / or supplier data follows the manufacturing process all the way to packaging, resulting in a fully customer-driven manufacturing process.

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Process scheme 2

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A support core composed of a fiber panel is manufactured in the desired format and is provided with a top side, a bottom side and edges. The top edge of the backing core is then sanded, after which a coat of white primer is applied. Next, a decoration is applied on the upper side by means of a digital four-color ink jet printer. Colors are magenta, yellow, cyan, and black. The decoration is positioned from a predetermined fixing point in the form of a corner of the support core, while the direction of the decoration is aligned with the long side edge starting at the same corner.

The basis for decoration is saved as digital data. This digital data has been obtained by digitizing a number of wood grain patterns with a digital camera. From the digital woodgrain images, a number of rectangular blocks with a fixed width, but variable length, are selected and separated. The width of the rectangular blocks is selected so that three block widths correspond to the width of a finished surface element. The digital image of the wood blocks is then digitally stitched together to form a rectangular surface of a specified size, for example 200 x 1200 mm. A selected number of such combinations of different blocks are designed as described above, so as to obtain a number of slightly different rectangular surfaces. The printer, or preferably a set of printers, is positioned so that a desired number of decorative rectangular surfaces are printed with a specific intermediate distance on the support core. The intermediate distance between the rectangular surfaces is the distance necessary to separate and mold the edges. Decoration printer (s) are also used to print fixing points at predetermined positions. Another printer, also guided by the computer, is used to print an identity code on the underside of each intended finished surface element.

This is followed by a base coat of UV curing acrylic lacquer using rollers. Subsequently, particles with an average particle size in the 150 μm range are sprayed onto the still wet base coat, whereby a top coat of UV-curing acrylic lacquer with a particulate additive is applied with a roller. hard with a mean size of 2 μm. Next, hard particles with an average size of 100 nm are sprayed on top of the wet top layer, whereby the lacquer is partially cured with UV light, thereby increasing the viscosity. The still soft lacquer is then endowed with a structure in the form of small, narrow, elongated recesses that simulate the pores of wood. This will increase the realism of the decoration. This is achieved by pressing the rollers towards the lacquered surface as it passes. The placement of the rollers is guided through the digitally recorded data used for the decoration printing, as well as the fixing point

ES 2 215 775 T3 used when more complex and fully matched surface structures are desired as described in conjunction with process scheme 1.

The lacquer is then fully cured with UV light to the desired strength, whereby the finished surface element is cut into predetermined formats that are to be provided with edges with bonding functionality and are milled molded. The edge molding and cutting process starts from a printed attachment point close to the decoration. The surface elements can then be inspected visually or by a computer-supported digital camera. The surface elements are then packaged in batches and provided with identification marks.

According to an alternative process in the process, it is possible to cut and mold the edges at an early stage of the process. It is suitable to apply and cure a protective layer of lacquer on top of the printed decoration followed by cutting and molding of the edges. The main and remaining part of the wear layer is then applied as described in relation to process scheme 1 or 2 above.

The above process will make it possible to have customer-driven manufacturing, where even very small quantities can be produced as efficiently as bulk manufacturing. Although only one decoration has been described in connection with the above process scheme, it is apparent to one skilled in the art that that decoration is very easily changed in the process. All important stages of manufacturing, such as printing, structuring, inspection, packaging and identification marking can be controlled and monitored with centralized treatment data.

The invention is also described by way of exemplary embodiments.

Example 1

A medium density fiber backing core panel was lightly sanded. A coat of primer lacquer was applied on top of the fiberboard. The primer layer was cured, after which a decoration was printed on top of the primer layer.

The build-up of a wear layer was then started by applying 30 g / m² UV curing acrylic lacquer by means of a roll coating. 20 g / m were sprayed² of hard particles made of α-aluminum oxide with an average particle size of 70 μm on the still sticky lacquer. The lacquer was then exposed to a predetermined amount of UV light energy so that it was only partially cured and the viscosity increased. Then a further 30 g / m roll coating was applied² of UV curing acrylic lacquer on the already applied layer, after which another 20 g / m was sprayed² of α-aluminum oxide particles with a mean particle size of 70 µm on the second still tacky coating. The lacquer was then exposed to a predetermined amount of UV light energy so that it was only partially cured and the viscosity increased. Next, three coats of UV curing acrylic lacquer were applied by roll coating with intermediate partial cure such as above. Each of the three layers had a surface weight of 20 g / m². The hard particles were completely embedded in the lacquer after the application of the three coats and a flat surface of the upper wear layer was obtained.

Next, a top coating process was started. A first layer of top coat UV curing acrylic lacquer was applied by means of a roller coating device on top of the partially cured previous coats. The topcoat lacquer contained 10 wt% α-aluminum oxide hard particles with a mean particle size of 10 µm. The first coat was applied at a surface weight of 10 g / m². The topcoat lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. A second coat of the topcoat lacquer was then applied and partially cured as described above. Subsequently, by means of a structured surface roller, the wear layer was provided with a surface structure. Next, a third layer of the top coat formulation was applied on top of the structured wear layer. Also, the third layer of the top coating was applied at a surface weight of 10 g / m². The wear layer was then exposed to a predetermined amount of UV light energy so that it was fully cured.

The wear layer was then tested for abrasion resistance according to ISO 4586 / 2-88, where an IP value of 7,100 revolutions was obtained. An IP value of 7,100 revolutions is sufficient for floor covering materials with medium to heavy traffic such as floors in hotel lobbies, corridors and the like. Example 2

A medium density fiber backing core panel was lightly sanded. A coat of primer lacquer was applied on top of the fiberboard. The primer layer was cured, after which a decoration was printed on top of the primer layer. The build-up of a wear layer was then started by applying 30 g / m² UV curing acrylic lacquer by means of a roll coating. 20 g / m were sprayed² of hard particles made of α-aluminum oxide with an average particle size of 70 μm on the still sticky lacquer. The lacquer was then exposed to a predetermined amount of

ES 2 215 775 T3 UV light energy, so that it only partially cured and increased the viscosity. Then a further 30 g / m roll coating was applied² of UV curing acrylic lacquer on the already applied layer, after which another 20 g / m was sprayed² of α-aluminum oxide particles with a mean particle size of 70 µm on the second still tacky coating. The lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. Next, three coats of UV curing acrylic lacquer were applied by roll coating with an intermediate cure as above. Each of the three layers had a surface weight of 20 g / m². The hard particles were completely embedded in the lacquer after the application of the three coats and a flat surface of the upper wear layer was obtained. The uppermost layer of the three lacquer layers was also cured to a desired viscosity.

A second decoration layer was then printed on top of the wear layer. The second decoration layer, which was identical to the first decoration closest to the core, was oriented and positioned so that it fully coincided with the first decoration.

The build-up of a top wear layer was then started by applying 30 g / m² UV curing acrylic lacquer by means of a roll coating. 20 g / m were sprayed² of hard particles made of α-aluminum oxide with an average particle size of 70 μιη on the still sticky lacquer. The lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. Then a further 30 g / m roll coating was applied² of UV curing acrylic lacquer on the already applied layer, after which another 20 g / m was sprayed² of α-aluminum oxide particles with a mean particle size of 70 µm on the second still tacky coating. The lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. Next, three coats of UV curing acrylic lacquer were applied by roll coating with an intermediate cure as above. Each of the three layers had a surface weight of 20 g / m². The hard particles were completely embedded in the lacquer after the application of the three coats and a flat surface of the upper wear layer was obtained.

Next, a top coating process was started. A first layer of top coat UV curing acrylic lacquer was applied by means of a roller coating device on top of the partially cured previous coats. The topcoat lacquer contained 10 wt% α-aluminum oxide hard particles with an average particle size of 10 gm. The first coat was applied at a surface weight of 10 g / m². The topcoat lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. A second coat of the topcoat lacquer was then applied and partially cured as described above. The wear layer was then provided with a surface structure by means of a structured surface roller. Next, a third layer of the top coat formulation was applied on top of the structured wear layer. Also, the third layer of the top coating was applied at a surface weight of 10 g / m². The wear layer was then exposed to a predetermined amount of UV light energy so that it was fully cured.

The wear layer was then tested for abrasion resistance according to ISO 4586 / 2-88, where an IP value of 13,500 revolutions was obtained. An IP value of 13,500 revolutions is fully sufficient for ground cover materials for denser traffic such as airports, railway stations and the like. The second decoration layer and the wear layer will add resistance to abrasion preventing unwanted blurring in the decoration.

Example 3

A medium density fiber backing core panel was lightly sanded. A coat of primer lacquer was applied on top of the fiberboard. The primer layer was cured, after which a decoration was printed on top of the primer layer.

The build-up of a wear layer was then started by applying 15 g / m² UV curing acrylic lacquer by means of a roll coating. 20 g / m were sprayed² of hard particles made of α-aluminum oxide with an average particle size of 70 μm on the still sticky lacquer. The lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. Next, a UV curing acrylic lacquer layer was applied by roll coating with intermediate partial cure such as above. The layer had a surface weight of 40 g / m². The hard particles were completely embedded in the lacquer after the application of the three coats and a flat surface of the upper wear layer was obtained.

Next, a top coating process was started. A first layer of top coat UV curing acrylic lacquer was applied by means of a roll coating device on top of the partially cured previous coats. The topcoat lacquer contained 10 wt% α-aluminum oxide hard particles with a mean particle size of 10 µm. The first coat was applied to a surface weight of 10 m / g². The topcoat lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. A second coat of the topcoat lacquer was then applied and partially cured as described.

ES 2 215 775 T3 above. The wear layer was then provided with a surface structure by means of a structured surface roller. Next, a third layer of the top coat formulation was applied on top of the structured wear layer. Also, the third layer of the top coat was applied to a surface weight of 10 g / m². The wear layer was then exposed to a predetermined amount of UV light energy so that it was fully cured.

Next, the wear layer was tested for abrasion resistance according to ISO4586 / 2-88, where an IP value of 3,100 revolutions was obtained. An IP value of 3,100 revolutions is fully sufficient for floor covering materials with light traffic, such as bedrooms, living rooms and the like.

Example 4

A medium density fiber backing core panel was lightly sanded. A coat of primer lacquer was applied on top of the fiberboard. The primer layer was cured, after which a decoration was printed on top of the primer layer.

The build-up of a wear layer was then started by applying 50 g / m² of UV curing acrylic lacquer containing hard 10% by weight α-aluminum oxide particles with a mean particle size of 10 µm by roll coating. The lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity.

Next, a top coating process was started. A first layer of top coat UV curing acrylic lacquer was applied by means of a roll coating device on top of the partially cured previous coats. The topcoat lacquer contained 10 wt% α-aluminum oxide hard particles with a mean particle size of 10 µm. The first layer was applied at a surface weight of 10 m / g². The topcoat lacquer was then exposed to a predetermined amount of UV light energy so that it only partially cured and increased in viscosity. A second coat of the topcoat lacquer was then applied and partially cured as described above. The wear layer was then provided with a surface structure by means of a structured surface roller. Next, a third layer of the top coat formulation was applied on top of the structured wear layer. Also, the third layer of the top coat was applied to a surface weight of 10 g / m². The wear layer was then exposed to a predetermined amount of UV light energy so that it was fully cured.

Next, the wear layer was tested for abrasion resistance according to ISO4586 / 2-88, where an IP value of 300 revolutions was obtained. An IP value of 300 revolutions could be sufficient for floor covering materials with light traffic, such as floors in bedrooms, living rooms and the like.

The invention is not limited to the embodiments shown, as these may vary in various ways within the scope of the claims. For example, it is possible to use so-called α-cellulose overlays impregnated with thermosetting resin instead of acrylic lacquer, in the process described in relation to process scheme 1 and, in particular, in the process described in relation to scheme 2 process. These α-cellulose sheets, which are impregnated with melamine-formaldehyde resin, are bonded to the support core by heat and pressure, whereby the resin is cured. Wear resistance can also be improved in this embodiment by adding hard particles in the range of 50 nm - 150 µm to the wear layer.