WO2006002917A2

WO2006002917A2 - Panel having a decorative surface

Info

Publication number: WO2006002917A2
Application number: PCT/EP2005/007050
Authority: WO
Inventors: Raimund Hagspiel
Original assignee: Fritz Egger Gmbh & Co.
Priority date: 2004-07-01
Filing date: 2005-06-30
Publication date: 2006-01-12
Also published as: DE502005009368D1; PL1761400T3; UA87315C2; EP1761400A2; RU2344940C2; RU2007103011A; DE102004032058B4; DE102004032058A1; WO2006002917A3; ES2341661T3; ATE463351T1; EP1761400B1

Abstract

The invention relates to a method for producing a panel which has a surface that is provided with a décor, said panel consisting of a lignocellulose-based supporting base. A priming layer is applied and smoothed with a smoothing device, thereby achieving an improved printed image. The invention also relates to a method which is characterized by applying a synthetic resin to the surface as the priming layer and/or as the sealing coating. The invention also relates to panels produced according to said method and to their use as floor plates or furniture panels.

Description

Plate with a decorative surface

The present invention relates to a method of making a panel having a decorative surface, the panel being made of a lignocellulosic material-based support material, such as a sheet metal. Chipboard, OSB board or fiber board is made. Likewise, the invention relates to a plate having a decor having a surface and a use of the plate as a floor panel or as a furniture board.

According to the current state of the art decorative surfaces are achieved on said substrates by coating with printed papers. These processes typically use a plurality of papers impregnated with synthetic resin, preferably melamine, melamine / urea or phenolic resins. At elevated pressure and temperature, these are then pressed either directly (Direct Pressure Laminate (DPL)) or only after their processing into a laminate with the substrate (High Pressure Laminate (HPL) or Continuous Pressure Laminate (CPL)). The papers containing the décor can be freely designed in their color, printed with any desired decors such as wood decors, tile or stone decors, fantasy decors and all other conceivable motifs and patterns.

To improve the abrasion resistance of the surfaces, it may be necessary for the use of the coated materials in the floor area or, for example, when used for table tops, the impregnated papers (laminates) with Hard solid particles equip to achieve appropriate resistance to superficial wear. For example, particles of quartz, nitrides and carbides SiO ₂ and corundum (OC-Al ₂ O ₃ ) are known. Recently, however, the use of very small particles of glass or diamond has become known here.

However, this approach to achieve a decorative surface on a lignocellulosic material-based carrier material is relatively expensive because of the necessary provision of laminates. An alternative technique has therefore been developed which achieves a decorative surface thereon by direct printing of the carrier material. Already widely used is the printing of workpieces to which lower demands are made in terms of optical quality, as is the case for example with back walls of cabinets. Developments to use such surfaces for workpieces, which are also subject to increased optical requirements due to their exposure according to the later intended use, but have so far led to no satisfactory results, since the desired optical properties such as sharpness and brilliance of the printed image could not be achieved.

According to the prior art, the following layers are applied to achieve a decorative surface on a lignocellulose-based carrier material depending on the intended use of the workpieces and the demands placed on their resistance, wherein a pre-treatment may precede by grinding: Primer: As a first treatment step, the surface to be treated is usually prepared with a primer (adhesion promoter) for a subsequent coating. The primer preferably consists of the same basic components as the subsequently applied layer.

Filler: These have the task on the one hand to reduce the absorption of the substrate and also to provide adhesion to the subsequent layers. Depending on the requirements arising from the later field of use of the workpieces and thus from the subsequently applied layers, it may be useful to apply the filler in two or more operations which may be an intermediate or at least partially hardened. In addition, the filler also serves to fill in irregularities in the surface in order to compensate for them.

Primer: This is applied after at least partial hardening of the filler. The purpose of the primer, which can also be built up again from different individual layers with intermediate or subsequent, at least partial curing, is to achieve the prevailing in the decor basic shade. For most wood finishes, coatings with beige to brown shades or even red shades are predominantly applied in this work step.

Printing ink: Depending on the color variety of the decoration to be applied and the desired lot sizes, the printing process known from the prior art, such as, for example, the stencil printing process or the offset printing process, is used in this step desired printed image applied. The use of digital printing methods is also already known for this field of application.

Sealing: Just as with the sealing of solid wood surfaces, with comparable methods a protection of the surface and also an improved visual appearance is achieved. The only difference is that it is a previously applied decor is coated and not a predetermined from the use of solid wood image. In addition to the upgrading of the decoration applied by the preceding step, protection against external influences should thus also be achieved in order to obtain the desired optical quality over the intended period of application. For example, by selecting the appropriate seal, the desired degree of gloss of the surface, a given scratch resistance or a specific abrasion resistance can be achieved. Depending on the various optical properties and the loads to be expected, the number of layers applied here is selected, which are optionally hardened in order to bring about a partial crosslinking coordinated with the subsequent steps. The predominantly used radiation-curable systems here can also contain hard particles to achieve high abrasion resistance. It is also possible to scatter the particles on a not yet or already partially cured layer in order to achieve the desired abrasionsresistenten properties. By selecting different particle sizes in or on the different layers, their use can be optimized, for example, the choice of small particle sizes in or on one of the upper layers has as proved to be favorable for achieving high abrasion resistance. Other additives such as so-called UV absorbers, which form an increased protection against UV radiation and so prevent unwanted premature yellowing, may be included in the seal to achieve desired optical properties or to obtain these over the intended period of application.

An opening provided for a subsequent grinding layer may be applied to the desired smoothness of the end product to achieve ^'between the sealing layers.

It is also possible to structure the surface in this, before a final curing, using a structured press plate or a structured roller, impress corresponding recesses, which can also come to rest in accordance with the previously applied decor to the finished product Material imaged by the decor improves to imitate. A further possibility of achieving such a structure, which is also referred to as a synchronous pore or as a real pore, is to achieve different application quantities of subsequent coatings in the different ink zones with the aid of printing inks having different wetting properties. Thus, the desired structure can be achieved depending on the decor. One can also call this structuring a chemical pore.

The systems used can be based on organic solvents or else be water-based. To harden the various layers, it is possible to adjust the temperature, UV radiation, ionizing radiation such as electron beams, or other methods and devices known for said purposes, may be used alone or in combination.

An advantage of printing on the panels, rather than laminating the panels with a laminate, is that a backing layer on the back of the panel can be avoided. As a result, the production costs can be further reduced.

All of the previously known embodiments, however, has the problem that for the achievement of a high-quality print quality given in lignocellulosic material based support materials, insufficient uniform surface texture or surface flatness is present, which also the rolling grain pre-applied layers, so their structure caused by their application itself, may have caused. This results in slightly different conditions in contact with the printing plates or printing cylinders. Despite the use of appropriately sized counter-pressure devices, therefore, no sharply delimited decor areas can be achieved, whereby the desired sharp boundaries in the printed image can not be achieved and can not achieve the desired decor quality. The creation of a highly regular and even surface by an elaborate pretreatment of the lignocellulosic material based carrier material with a variety of, usually very expensive methods has not been able to provide the desired result. The reason for this deteriorated print quality lies in the rolling grain of the paints itself, ie the structure in the applied layers by the application itself.

The image in particular is also impaired by the fact that the roughness of the surface leads to a running of the individual pixels with each other. Even if, for example, it has been printed with a resolution of 54 dots per cm or 2,916 dots per cm ² , the picture shows a lower resolution, since the pixels are no longer clearly separated from each other.

A further disadvantage with the previous printing technique is that the used, usually UV-curable paints for the primer and the seal are expensive per se. Furthermore, you need UV lamps for curing the different layers of paint. The production costs are therefore considerable ..

Finally, there is a disadvantage in that the lacquer layers have to be ground, as a result of which an expensive material is removed again, resulting in a considerable amount of dust which has to be reliably sucked off and removed within the production device.

The present invention is therefore based on the technical problem of providing a method by means of which decorative surfaces with improved optical properties can be obtained on sheets of a carrier material based on lignocellulosic material by direct printing. The aim is to produce optical properties of such quality that the panels produced from them are also used in areas may have to meet increased visual requirements due to their exposure.

Another technical problem is that the paint layers are to be avoided in whole or in part in order to minimize manufacturing costs and production costs.

Finally, a further technical problem lies in the fact that the grinding processes required in the previous production of the painted surfaces can be minimized or completely avoided, in particular in the case of the UV coating layers used.

The above-indicated technical problems are achieved by the method with the features of claim 1, 22 and 31 according to the invention. Likewise, the technical problem is solved by the plates according to claims 37, 38, 39 and 45 and by their applications according to claims 52 and 53. Further embodiments of this method are specified in the respective dependent claims.

In order to achieve the substrate required for an optimal print image, a smoothing of the surface by means of a smoothing device is provided according to the invention prior to printing on the carrier material based on lignocellulosic material. The smoothing device equalizes any irregularities in the surface after priming and thus achieves an optimally flat surface.

Any fibers still projecting from the primer or the so-called cloudiness which arises on the end product as a result of different coating thicknesses before printing can be used be prevented, which is caused by a non-uniformity of the color of the surface to be printed, so due to a shine through the substrate. The reason for printing, ie the primed surface, is thus characterized by an improved suitability for achieving a high-quality printing quality, which in addition to the regularity and reproducibility also has a particularly good sharpness and brilliance of the printed image.

As a measure of the sharpness of the printed image can be achieved with the inventive method resolution of more than 54 points per cm bzs. 2,916 points per cm ² , in particular greater than or equal to 60 points per cm or 3,600 points per cm ² . In particular, a resolution of greater than or equal to 70 points per cm or 4,900 points per cm ² can be achieved.

In the implementation of the inventive method, it is preferred that the smoothing be carried out shortly before printing, ie in particular within a period of time of less than 1 minute, preferably less than 10 seconds and preferably less than 5 seconds before printing.

Particularly suitable for smoothing before printing devices have proven that work on the ironing principle and have a contact surface. In addition to a mechanical contact, a defined temperature is applied to the surface.

The contact between the surface to be smoothed and the contact surface is preferably over the entire surface. Therefore, the entire surface to be smoothed comes into contact brought with the contact surface. It is advantageous that the entire surface is brought evenly into contact with the contact surface.

The contact surface is formed substantially flat in a first embodiment, so that at least in each case a flat portion of the surface comes into contact with the contact surface. This method thus offers itself in a clocking process.

This can also be done by a roller which is arranged so that the surface to be coated comes into contact with it immediately before printing along a line of contact with it. As a result of the continuous movement, the surface is completely smoothed. Rolling technology therefore lends itself to continuous processes.

Such a roller can be driven with the aid of suitable drive means, for example by means of a motor, and exert a relative movement to the machined surface by rotation in co-rotation or counter-rotation. Likewise, the roller can be moved so that no relative movement between the roller surface and the surface of the plate is formed.

Another possibility for achieving the desired ironing effect is to arrange the heatable rollers at an angle, so that their axis of rotation extends in another than at right angles to the direction of movement of the surface to be treated. Thus, a relative movement of the surfaces in contact can be achieved, which will be different depending on the degree of rotation axis deviation. The dabai occurring steering effects by the inclination The roller must be taken into account when transporting the plate.

A similar effect can be achieved with rollers oscillating along the axis. This increases the uniformity of the smoothing, in particular in connection with a rotation of the roller. In this case, a positive guidance of the plate is advantageous in order to allow a controlled guiding of the plate and to prevent slipping of the plate.

The applied contact pressure, which is exerted by the smoothing device on the surface to be treated, is preferably kept constant during the application of the method. The Andruckdurck is to at least depending on the design of the smoothing device, the selected relative speed between the smoothing device and the plate, the type of carrier material, the composition of the primer and the

Feed rate adjusted. Proven combinations of these parameters can be stored electronically, which can be adjusted automatically when changing the feed rate or another parameter, all others.

The result of smoothing is also due to the design of the contact surface of the

Smoothing influenced. In addition to polished, metallic materials, coated metals can also be used, with coatings based on Teflon having proven suitable as coatings. Likewise, hard chromium-plated or nickel-plated metal surfaces or plastics or coated plastics can be used. This gives a high surface smoothness favorable thermal properties, whereby a good ironing effect can be achieved.

The surface smoothness of the smoothing tool can be characterized with values of 0.06 to 6 μm roughness.

As tests have shown, the achievement of a good smoothing is not necessarily bound to the smoothness of the contact surface of the smoother. When using metal, tests were carried out with structured or microstructured surfaces, some of which could at least give equally good results. As a surface structure, all regular or irregular line patterns with intervening depressions come into question. The structure can have a depth or amplitude of about 0.5 mm.

Also, by wetting the smoothing means with water or liquids containing the matched additives, effects for optimizing the smoothing process can be achieved.

In order to achieve increased feed rates in a coating system with a smoothing device according to the invention for improved system utilization, it may be useful to arrange a plurality of smoothing devices in succession in order to achieve the desired surface quality before the compression stage.

Previously, the invention has been described in terms of smoothing one or more layers. In the following, a further aspect of the invention is discussed, which is independent of the smoothing and also improves the quality of the painted plate. It is about the replacement of one or more primer, dye and / or Coating layers by a synthetic resin, which preferably consists of a polyurethane-based synthetic resin system. resin

According to the invention, the above-indicated technical problem is also solved by a method for producing a plate having a surface comprising a decor, wherein the plate consists of a carrier material based on lignocellulosic material, in which the surface to be decorated is primed with at least one primer layer in which the primed surface is printed to produce the decoration, wherein the printed surface is sealed with at least one sealing layer and wherein at least one primer layer is applied as a synthetic resin layer.

With this method, particularly good results could be achieved, in particular when smoothing the primer layer. Instead of a primer varnish, a synthetic resin system is used. Due to the achievable higher layer thicknesses and the improved

Adhesive properties of this type of primer could be dispensed with the usual use of a filler, and the primer as well as on UV coatings. The resulting cost savings are significant. Because in addition to a significantly smaller size of the manufacturing plant by reducing the processing stages, the cost savings is achieved by cheaper substances.

The order quantities are from 40 to 100 g / m ² . The exact order quantities depend on the surface to be coated and the synthetic resin used. Preferably, a resin system based on polyurethane is applied as synthetic resin. This type of resin system is known and has already proven itself in other applications. As a resin system, other systems may be used, for example, those based on epoxy resins or polyester resins. In general, it is also possible to characterize the synthetic resins that can be used in that both thermoplastic and thermosetting synthetic resins come into question.

In some applications, it has proved to be advantageous that a bonding agent is applied to the surface to be printed in front of the at least one primer layer of synthetic resin. As a result, the connection of the synthetic resin to the surface of the carrier material could be improved.

An advantage of using a resin system for the primer layer is that the resin layer itself can be color matched to the primer color to be achieved. Thus, one obtains a finished primer for the subsequent printing of the decor in one step.

In some cases, the coloring of the resin is difficult to adjust. In these cases, it is advantageous if after the primer layer of synthetic resin, a further primer layer of a coloring paint existing primer is applied. This application can be more reliable and, if necessary, less expensive than coloring the synthetic resin itself. It depends on the individual case, whether it is advantageous to color the resin itself or to apply an additional, coloring paint.

Another advantage of using a synthetic resin layer as a primer is the ability of the resin to be smoothed in a simple manner. For smoothing, a method can be used which has already been explained above for smoothing a primer consisting of a lacquer.

According to the invention, the above-indicated technical problem is also solved by a method for producing a plate having a surface comprising a decor, wherein the plate consists of a carrier material based on lignocellulosic material, in which the surface to be decorated is primed with at least one primer layer in which the primed surface is printed to produce the decor, wherein the printed surface is sealed with at least one sealing layer and wherein at least one sealing layer is applied as a synthetic resin layer.

It has also proven advantageous in the case of the sealing layer that this layer is produced from a synthetic resin. Since the cured synthetic resin layer has good abrasion values and hardness values, the use of a synthetic resin layer as a sealing layer largely avoids the expensive UV-curable coatings containing microparticles or nanoparticles.

As order quantities, values of 40 to 100 g / m ² are also suitable. The exact order quantities depend on the to be coated surface and the resin used.

For the sealing layer is also valid that this can be improved by the addition of particles, for example. From corundum, silica or glass, in their abrasion resistance.

A further advantage is that the grinding operations required in the application of paints are avoided both in the production of a primer layer and in the production of a sealing layer. Because the synthetic resin layer can be smoothed without a subsequent grinding so that the resulting surface meets the requirements. The omission of the grinding operations means in particular for the process a significant advantage, because the resulting dusts do not need to be removed and disposed of, but the occurring during grinding material loss is completely avoided. In particular, the grinding of the paints has led to an expensive loss of material, which completely avoids the invention.

In special cases, it has proven to be advantageous that, prior to the application of the at least one sealing layer made of synthetic resin, a lacquer layer containing particles, preferably a lacquer layer having corundum particles, is applied to the printed surface. The cost advantage is given up in this case to a part, but the abrasion resistance is increased, so that the method is also suitable for the production of plates with particularly high demands. However, the lacquer layer does not have to be ground before the synthetic resin layer is applied. The paint layer is preferably cured with UV radiation. Furthermore, the lacquer layer has particles with an average particle size of 1 to 100 μm.

In a further preferred embodiment, after application of the at least one sealing layer made of synthetic resin, a particle-containing lacquer layer is applied, which is preferably cured with UV radiation and in particular contains particles having an average size of 100 nra to 1 μm (nanoparticles). The particles are preferably made of mineral-based materials such as silica or glass. It is therefore a so-called nano-lacquer. Also, this embodiment of the method has been found to be advantageous for applications with particularly high demands on the surface hardness, even if a part of the cost advantage described above is abandoned.

A further embodiment of the method is that the surface of the sealing layer or the lacquer layer is provided with a surface structure. Thus, in particular, a surface structure can be created that is in accordance with the decorative image. Thus, for example, wood patterns can be imitated faithfully if both the optical pattern matches the haptic pattern.

According to the invention, the above-indicated technical problem is also solved by a plate having a carrier material based on lignocellulosic material, a surface having a primer layer and a decor printed on the primer layer, the primer layer having a roughness depth of less than 15 μm. A roughness depth is preferred less than 10 μm, in which case the requirements for the smoothing tools and their use are increased. In a particularly good setting even a surface roughness of 6 to 8 microns can be achieved, has.

This low roughness can be produced in particular by the above-described smoothing method, which is also part of the invention. The low roughness allows an unprecedented image quality.

The technical problem indicated above is also solved according to the invention by a plate with a carrier material based on lignocellulosic material, with a surface having a primer layer and with a decoration printed on the primer layer, wherein the print image has a resolution of more than 54 points per cm, in particular greater equal to 60 points per cm, preferably greater than or equal to 70 points per cm.

The high print quality can be achieved in particular by the application of the method according to the invention described above. In particular, the print quality can be achieved by the previously explained low roughness of the surface of the primer layer.

Furthermore, the technical problem indicated above is also solved according to the invention by a plate having a carrier material based on lignocellulosic material, a surface having a primer layer and a decor printed on the primer layer, wherein the primer layer at least partially consists of a synthetic resin. The synthetic resin preferably consists of a polyurethane-based synthetic resin system. In this layer construction, a number of steps are avoided on the one hand in the manufacture of the plate. On the other hand, the previously expensive materials are replaced by a cheaper material.

In order to achieve a better adhesion of the synthetic resin to the carrier material, a layer consisting of an adhesion promoter is preferably arranged between the carrier material and the primer layer consisting of synthetic resin.

Furthermore, the primer layer made of synthetic resin may be color-matched to the primer color to be achieved. This allows a direct printing of the primer layer, without the need for another layer. However, this is only possible as far as that the resin can be colored with the desired color.

If this can not be ensured, it is provided that a primer consisting of a lacquer is arranged on the primer layer consisting of synthetic resin. The existing of a conventional primer primer can be easily adapted to the desired color.

It is further preferred that the primer layer made of synthetic resin has a surface roughness of less than 15 microns, in particular of less than 10 microns, preferably from 6 to 8 microns. In this case, a good print quality can be achieved, which allows an improved and thus even more faithful reproduction of subjects. The technical problem indicated above is also achieved according to the invention by a plate having a lignocellulosic material-based carrier material, a surface having a primer layer, a decor printed on the undercoat layer, and a sealant layer applied to the printed decor, at least the sealant layer partially made of a synthetic resin. Again, the synthetic resin is preferably made of a polyurethane based resin system.

Thus, it has been recognized in the present invention that not only the primer layer but also the sealant layer can be made of a resin system. Because it has been recognized - that the hardness and abrasion resistance of the resin sufficient for a number of plate application, without a UV-curable sealing lacquer is needed. For a variety of applications, these properties are sufficient and the manufacturing cost of the board can be reduced.

If the requirements for the properties of the sealing layer are greater than can be achieved with the sealing layer consisting of a synthetic resin, then it has proven to be advantageous if a particle-containing lacquer layer, preferably a corundum particle, is present between the printed decorative layer and the sealing layer consisting of synthetic resin Paint layer is arranged. This lacquer layer preferably has particles with an average particle size of 1 to 100 μm. Even larger particle sizes are possible. Likewise, a particle-containing lacquer layer can be arranged on the sealing layer made of synthetic resin, wherein here too the lacquer layer can be cured with UV radiation. The lacquer layer preferably has particles with a mean size of 100 m to 1 μm. This additional layer can be used to improve surface hardness and abrasion resistance for special applications.

It is also preferred in this embodiment of the invention if the surface of the sealing layer or the lacquer layer has a surface structure. Thus, can. also in this case, a match between the optical pattern and the haptic pattern can be achieved.

Previously, a number of embodiments of the invention have been explained by way of examples of the methods and the plates produced therewith. The plates themselves can be used in many ways. However, it is preferred to use the plates either for a floor panel or for a furniture part. Because in both applications, it depends on special surface properties that can be achieved with the present invention in an advantageous manner.

In the following, examples of the methods and the plates produced therewith are explained.

Example 1:

Production of a floor panel with smoothing of the primer layer For the production of a floor panel, an already ground medium density fibreboard (MDF board) with a thickness of 5.8 mm and a density of about 660 to 900 kg / m ³ in a system in which successively primer, filler, primer, printing ink and Seal can be applied, retracted. After a brushing station, which removes any impurities or grinding dust, about 15 g / m ² are applied by means of applicator rolls in a first stage and about 25 g / m ^{2 of} filler in a second stage, wherein an intermediate drying always follows. In turn, in one stage or in two stages, the primer held in the basic shade of the desired décor is rolled onto the base material of this type, wherein in each case about 15 g / m ^{2 are} applied and again after each application a partial drying follows.

Now, at a feed rate of, for example, 32 m / min with the aid of heated to 160 ⁰ C, polished steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m over the width of Plate of the smoothing process according to the invention. The thus treated plate has over its entire surface a level in color, texture and gloss level surface. Also, no fibers that extend from the substrate into the coating film can be seen. The fibers can still be recognizable in the surface after smoothing.

Immediately following the smoothing device, a wood decor is printed on three printing units which are composed of a printing cylinder with dyeing and dampening rollers and a blanket cylinder with counter-pressure cylinder. This procedure is also called indirect Teifdruck called. Likewise, other printing techniques can be used, for example. Offset printing method.

As a seal of the surface obtained, a UV-curable coating system is applied in three parts. The first part consists of two corundum-containing layers of about 35 g / m ² order quantity, each with subsequent intermediate curing. This is followed by a non-corundum UV varnish which, after intermediate curing in a subsequent intermediate sanding with grits 280 and 320, causes an additional leveling of the surface.

The final part of the sealing then forms an applied again in two stages, provided with corundum UV curable coating layer with, for example, 7 ^~ and 8 g / m ² application amount, wherein the corundum particles contained here on average smaller particle sizes than the particles of the previous lacquer layers , Here, too, every coating application is followed by intermediate hardening. If desired, this step can be followed by embossing a surface profile.

In the final final cure of the coating composition, the final cross-linking of the various components is effected.

The plates obtained are separated after a lying time of about 24 hours for temperature compensation and post-curing in a conventional manner to panels, provided with edge profiles and packaged. The resulting floor panels are characterized by a regular, brilliant appearance and precise contrasts in the decor.

When tested according to the methods given in prEN 14354 (2001) Wood materials - Veneered floor coverings, the criteria of resistance to impact, thickness swelling, resistance to impact, resistance to wear, scratch resistance and resistance to chemical substances could be met, so that the floor panels of this class are of the stress class 31 (suitable for moderate commercial use) can be assigned. Likewise, the standard prEN 13329 for laminate flooring can be met at least partially. For example, the requirements for strength against cigarette heat are not met.

Example 2:

Production of a furniture panel with smoothing of the primer layer

To produce a worktop for the office area, a 24 mm thick, sanded chipboard with a density of 590 kg / m ^{3 is} coated in the rolling process with a pigmented hotmelt adhesive.

After Zwisσhenhärtung takes place in the smoothing device according to the invention, the contact surface here consists of a Teflon-coated steel roller, which oscillates over its longitudinal axis at 12 short strokes (about 4 cm) per second with a relative speed of 33 m / s (corresponding to a roll diameter of 350 mm about a speed of 1800 min ^"1 ) in the mating and a Contact pressure of 180 N / m moves, the smoothing and thus providing the desired, optimal printing reason instead.

The subsequent printing of the plate takes place in the device described in Example 1. To protect the applied decoration, only two layers of UV-curable, abrasion-resistant particles containing coating layers of 15 g / m ² order quantity are provided here due to the lower requirements in terms of abrasion resistance of the surface, which are hardened after the order.

Before the final final curing of the coating, the plate is still provided with the aid of an embossing roller with a structure that is intended to cause a lower gloss level, so that grip marks as they are expected in office furniture surfaces, optically less prominent. The gloss level can also be adjusted chemically in the paint itself. Incidentally, the embossing roll can also be used for introducing a surface profiling in order to produce a profiling which matches the decor.

The resulting decorative surface of the thus treated plate is characterized by the high-quality decorative image, in comparison to the conventional laminate coating, lower resulting production costs.

Example 3:

Production of a plate with a primer of a synthetic resin layer To produce a panel which can be used, for example, as a floor panel, an already ground medium-density fiberboard (MDF panel) with a thickness of 5.8 mm and a density of about 660 to 900 kg / m ³ in a plant in the successively primer, ink and seal can be applied, retracted. After a brushing station which removes any impurities or sanding dust, a primer made of a polyurethane-based resin system is applied by means of applicator rollers at an application rate of about 70 g / m ² . The primer layer is applied in the heated state.

The synthetic resin has been provided with a coloration before application, so that the resulting primer layer is suitable for direct printing.

In further tests, it has proven to be an advantage that the applied primer layer is initially only partially cooled and smoothed by means of a smoothing device.

For this purpose, at a feed rate of, for example, 32 m / min with the aid of heated to 160 ⁰ C, polished steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m over the width of Plate of the smoothing process according to the invention. The thus treated plate has over its entire surface a level in color, texture and gloss level surface. Also, no fibers that extend from the substrate into the coating film can be seen. Subsequently, with or without smoothing, the synthetic resin layer is completely solidified by cooling. Likewise, hardening can also be achieved by using radiation.

Immediately following the smoothing device, a wood decor is printed on three printing units which are composed of a printing cylinder with dyeing and dampening rollers and a blanket cylinder with counter-pressure cylinder.

The final part of the sealing then forms an applied again in two stages, provided with corundum particles UV-curable lacquer layer with, for example, 7 and 8 g / m ² application amount, wherein the corundum particles contained here have on average smaller particle sizes than the particles of the previous lacquer layers. Here, too, every coating application is followed by intermediate hardening. If desired, this step can be followed by embossing a surface profile.

In the final final cure of the coating composition, the final cross-linking of the various components is effected. The resulting panels are characterized by a regular, brilliant appearance and precise contrasts in the decor.

Example 4

Production of a plate with a seal of a synthetic resin layer

To produce a panel that can also be used as a floor panel, an already ground medium density fiberboard (MDF panel) with a thickness of 5.8 mm and a density of about 660 to 900 kg / m ³ in a plant in the successively primer, filler, primer, ink and sealant can be applied, retracted. After a brushing station, which removes any impurities or grinding dust, about 15 g / m ² are applied by means of applicator rolls in a first stage and about 25 g / m ^{2 of} filler in a second stage, wherein an intermediate drying always follows. In turn, in one stage or in two stages, the primer held in the basic shade of the desired décor is rolled onto the base material of this type, wherein in each case about 15 g / m ^{2 are} applied and again after each application a partial drying follows.

Now, at a feed rate of, for example, 32 m / min with the aid of heated to 160 ⁰ C, polished steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m over the width of Plate of the smoothing process according to the invention. The thus treated plate has over its entire surface a level in color, texture and gloss level surface. Also, there are no fibers coming out of the Substrate in the coating film rich, recognizable. The fibers can still be recognizable in the surface after smoothing.

As a seal of the obtained surface, a sealing layer made of a polyurethane based resin system is applied by means of applicator rollers. The order quantity is 70 g / m ² .

During application, the polyurethane-based resin is heated to ensure proper processing.

In further tests, it has proven to be an advantage that the applied sealing layer is initially only partially cooled and smoothed by means of a smoothing device.

For this purpose, at a feed rate of, for example, 32 m / min with the aid of heated to 160 ⁰ C, polished steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m over the width of Plate of the smoothing process according to the invention. The thus treated plate has over its entire surface a level in color, texture and gloss level surface. Also, no fibers that extend from the substrate into the coating film can be seen. Subsequently, with or without smoothing, the synthetic resin layer is completely solidified by cooling.

The resulting panels are characterized by a regular, brilliant appearance and precise contrasts in the decor.

Example 5:

Production of a board with a primer made of a synthetic resin layer and with a seal of a synthetic resin layer

To produce a panel which can be used, for example, as a floor panel, an already ground medium-density fiberboard (MDF panel) with a thickness of 5.8 mm and a density of about 660 to 900 kg / m ³ in a plant in the successively primer, ink and seal can be applied, retracted. After a brushing station, which removes any impurities or grinding dust, about 70 g / m ² a primer made of a polyurethane-based resin system are applied by applicator rollers. The primer layer is applied in the heated state.

In further tests, it has proven to be an advantage that the applied primer layer initially only partially is cooled and smoothed by means of a smoothing device.

For this purpose, at a feed rate of, for example, 32 m / min with the help of tempered at 160 ⁰ C ^' polished ^' steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m across the width the plate of the smoothing process according to the invention. The thus treated plate has over its entire surface a level in color, texture and gloss level surface. Also, no fibers that extend from the substrate into the coating film can be seen.

Subsequently, with or without smoothing, the synthetic resin layer is completely solidified by cooling.

As a seal of the obtained surface, a sealing layer made of a polyurethane-based resin system is applied by means of applicator rollers. The order quantity is 70 g / m ² .

During application, the polyurethane resin is heated to ensure proper processing.

In further tests, it has proven to be an advantage that the applied sealing layer is initially only partially cooled and smoothed by means of a smoothing device. For this purpose, at a feed rate of, for example, 32 m / min with the aid of heated to 160 ⁰ C, polished steel rollers with a relative speed of about 0 to 10 m / min and with a contact pressure of about 50 to 100 N / m over the width of Plate of the smoothing process according to the invention. The thus treated plate has over its entire surface on a level in color, structure and gloss level .Oberfläche. Also, no fibers that extend from the substrate into the coating film are recognizable.

Claims

PATENT APPLICATIONS

A method of making a panel having a decorative surface, the panel being made of a lignocellulosic material-based support material, wherein the surface to be decorated is primed, wherein the primed surface is smoothed and smoothed Surface is printed to produce the decor.

2. The method of claim 1, wherein the surface is smoothed in a short time interval before printing.

3. The method of claim 1 or 2, wherein the surface is smoothed by contact with at least one contact surface of a smoothing device.

4. The method of claim 3, wherein the contact surface is tempered.

5. The method of claim 3 or 4, wherein the surface is brought over the entire surface in contact with the contact surface.

6. The method according to any one of claims 3 to 5, wherein the contact surface is formed by the surface of a substantially flat plate.

7. The method according to any one of claims 3 to 5, wherein the contact surface is formed by the surface of at least one roller.

8. The method of claim 7, wherein by a rotation of the roller, a relative movement between the surface to be smoothed and the contact surface of the roller is generated.

9.- The method of claim 8, wherein the axis of rotation of the roller is aligned obliquely to the direction of movement of the surface.

10. The method according to any one of claims 7 to 9, wherein the roller is driven in the longitudinal direction to an oscillating movement.

11. The method according to any one of claims 3 to 10, wherein the contact surface is pressed against the surface.

12. The method according to any one of claims 3 to 11, wherein a contact surface is applied with a smooth, in particular polished contact surface.

13. The method according to any one of claims 3 to 11, wherein a contact surface with a structured, in particular microstructured contact surface is applied.

14. The method according to any one of claims 3 to 13, wherein the contact surface consists of a metal.

15. The method according to any one of claims 3 to 13, wherein the contact surface consists of a coated, in particular coated with Teflon metal.

16. The method according to any one of claims 3 to 13, wherein the contact surface consists of a plastic, in particular of a plastic coated with Teflon.

17. The method according to any one of claims 3 to 16, wherein the contact surface is wetted with a liquid.

18. The method of claim 17, wherein the contact surface is wetted with water or with a liquid containing additives.

19. The method according to any one of claims 1 to 18, wherein a primer is applied to the surface to be printed before priming.

20. The method according to any one of claims 1 to 19, wherein the printed image is applied with a resolution of more than 54 points per cm, in particular greater than or equal to 60 points per cm, preferably greater than or equal to 70 points per cm.

21. The method according to any one of claims 1 to 20, wherein after printing the surface is sealed.

22. A method of manufacturing a panel having a decorative surface, the panel comprising one based on lignocellulosic material

Carrier material is in which the surface to be decorated with the primer is primed with at least one primer, wherein the at least one primer layer as

Synthetic resin layer is applied, wherein the primed surface for producing the

Decor is printed and in which the printed surface with at least one

Sealing layer is sealed.

23. The method according to claim 22, wherein a resin system based on polyurethane is applied as the synthetic resin.

24. The method of claim 22 or 23, wherein before the at least one primer layer of synthetic resin, a bonding agent is applied to the surface to be printed.

25. The method according to any one of claims 22 to 24, wherein the synthetic resin layer is color matched to the primer color to be achieved.

26. The method according to any one of claims 22 to 25, wherein after the primer layer of synthetic resin, a further consisting of a lacquer primer is applied.

27. The method according to any one of claims 22 to 26, wherein the primer layer of synthetic resin is smoothed after application by a method according to any one of claims 1 to 18.

28. The method according to any one of claims 22 to 27, wherein prior to the application of the at least one sealing layer of synthetic resin, a particle-containing lacquer layer, preferably a corundum particles having lacquer layer is applied to the printed surface.

29. The method of claim 28, wherein the lacquer layer is cured with UV radiation.

30. The method of claim 28 or 29, wherein the resist layer particles having a mean size of 1 to 100 microns.

31. A method of producing a panel having a decorating surface, the panel being of a lignocellulosic material-based carrier material, wherein the surface to be decorated with is primed with at least one primer layer, wherein the primed surface for creating the primer layer

Decor is printed, in which the printed surface with at least one

Sealing layer is sealed and the at least one sealing layer as

Synthetic resin layer is applied.

32. The method according to claim 31, wherein a resin system based on polyurethane is applied as the synthetic resin. ^'

33. The method of claim 31 or 32, wherein after the application of the at least one sealing layer of synthetic resin, a particle-containing paint layer is applied.

34. The method of claim 33, wherein the lacquer layer is cured with UV radiation.

35. The method of claim 33 or 34, wherein the resist layer particles having a mean size of 100 nm to 1 micron.

36. The method according to any one of claims 31 to 35, wherein the surface of the sealing layer or the paint layer is provided with a surface structure.

37. Plate with a lignocellulosic material

Carrier material, with one having a primer layer

Surface and with a printed on the primer layer

Decor, characterized in that the primer layer has a surface roughness of less than 15 microns, in particular less than 10 microns, preferably from 6 to 8 microns.

38. Plate with a lignocellulosic material

Carrier material, having a primer layer having

Surface and with a printed on the primer layer

Decor, characterized in that the printed image has a resolution of greater than or equal to 60

Points per cm.

39. plate having a carrier material based on lignocellulosic material,

with a surface having a primer layer and with a decoration printed on the primer layer, characterized in that the primer layer at least partially consists of a synthetic resin.

40. Plate according to claim 39, characterized in that the synthetic resin consists of a synthetic resin system based on polyurethane.

41. Plate according to claim 39 or 40, characterized in that between the carrier material and the existing of synthetic resin primer layer consisting of a primer layer is arranged.

42. Plate according to one of claims 39 or 41, characterized in that the primer layer made of synthetic resin is adapted in color to the primer dye to be achieved.

43. Plate according to one of claims 39 or 42, characterized in that on the existing of synthetic resin primer layer consisting of a paint primer is arranged.

44. Plate according to one of claims 39 or 43, characterized in that the existing of synthetic resin primer layer has a surface roughness of less than 15 microns, in particular less than 10 microns, preferably from 6 to 8 microns.

45. plate with a lignocellulosic material based

Carrier material, having a primer layer having

Surface, with a printed on the primer layer

Decor and with a applied on the printed decor

Sealing layer, characterized in that the sealing layer consists at least partially of a synthetic resin.

46. Plate according to claim 45, characterized in that the synthetic resin consists of a polyurethane-based synthetic resin system.

47. Plate according to claim 45 or 46, characterized in that between the printed decorative layer and the sealing layer made of synthetic resin, a particle-containing lacquer layer, preferably a corundum particles having lacquer layer is arranged.

48. Plate according to claim 47, characterized in that the lacquer layer has particles with a mean size of 1 to 100 microns.

49. Plate according to one of claims 45 to 48, characterized in that a particle-containing lacquer layer is arranged on the sealing layer consisting of synthetic resin.

50. Plate according to claim 49, characterized in that the lacquer layer has particles with a mean size of 100 nm to 1 micron.

51. Plate according to one of claims 45 to 50, characterized in that the surface of the sealing layer or the lacquer layer has a surface structure.

52. Use of a plate according to one of claims 37 to 51 for a floor panel.

53. Use of a plate according to one of claims 37 to 51 for a Möbeltei1.