Method for laser etching and/or laser embossing and powder coating a substrate

• US 20090071941A1
• Filed: 07/14/2008
• Published: 03/19/2009
• Est. Priority Date: 09/14/2007
• Status: Abandoned Application

• Current Assignee: DVUV LLC
• Original Assignee: DVUV LLC
• Inventors: Miller, William, Knoblauch, Michael F.
• Application Number:
  US12/218,344
• Publication Number:
  US 20090071941A1
• Time in Patent Office: Days
• US Class Current: 216/94
• CPC Class Codes: B23K 2103/36 Wood or similar materials
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/0838 by using an endless conveyor belt
• CPC Class Codes: B41M 5/24 Ablative recording, e.g. by burning marks; Spark recording marking by high energetic means, e.g. by laser otherwise than burning or ablative removal B41M5/26; materials or methods for recording or reproduction by optical means G11B7/00
• CPC Class Codes: B41M 7/0045 using protective coatings or film forming compositions cured by mechanical wave energy, e.g. ultrasonics, cured by electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams, or cured by magnetic or electric fields, e.g. electric discharge, plasma
• CPC Class Codes: B41M 7/0054 using protective coatings or film forming compositions cured by thermal means, e.g. infrared radiation, heat
• CPC Class Codes: B44C 1/228 by laser radiation
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44F 9/02 wood grain effects

Abstract

A method for finishing a substrate including transferring an image onto the substrate and powder coating the substrate. Embodiments provide methods for producing simulated wood grain finishes on engineered wood products such as medium density fiberboard. Logos, graphics, text, and the like may be embossed and/or etched onto the substrate using a laser. In alternative embodiments, the substrate may comprise a solid polymer.

Claims

1. A method for finishing a substrate, comprising the steps of:

transferring at least a first image onto a substrate using at least one of laser embossing and laser etching;

coating the substrate with a powder coating; and

curing the powder coating.

2. The method of claim 1, further comprising a step of transferring a second image onto the substrate using at least one of laser embossing and laser etching.

3. The method of claim 1, wherein the first image comprises wood grain.

4. The method of claim 1, wherein the first image comprises at least one of a graphic, pattern, design, logo, character, text, likeness, picture, and texture.

5. The method of claim 2, wherein the first image comprises wood grain and the second image comprises at least one of a graphic, design, logo, character, text, likeness, and picture.

6. The method of claim 1, wherein the substrate comprises an engineered wood product.

7. The method of claim 6, wherein the engineered wood product comprises medium density fiberboard.

8. The method of claim 1, wherein the substrate comprises a solid polymer.

9. The method of claim 1, wherein the powder coating is a resin based powder coating that cures to be substantially transparent.

10. The method of claim 9, wherein the powder coating is an ultra-violet light curable powder coat and the curing step uses ultra-violet light to cure the powder coat.

11. The method of claim 9, wherein the powder coat is a thermosetting powder coat composition and the curing step uses heat to cure the powder coat.

12. A method for finishing a substrate, comprising the steps of:

providing a substrate comprising medium density fiberboard;

transferring at least a first image comprising a wood grain onto the substrate using at least one of laser embossing and laser etching;

preheating the substrate;

electro-static powder coating the substrate with a powder coat;

heating the substrate to cause the powder coat to at least one of gel and flow; and

curing the powder coat using ultra-violet light.

13. The method of claim 12, further comprising the step of, prior to the powder coating step:

transferring a second image onto the substrate using at least one of laser embossing and laser etching.

14. The method of claim 13, wherein the second images comprises at least one of a graphic, pattern, design, logo, character, text, likeness, and picture.

15. The method of claim 13, further including the steps of manipulating the first image and manipulating the second image, prior to the transferring steps, wherein the manipulating steps include at least one of cropping, rotating, resizing, or copying.

16. The method of claim 13, wherein the first image and the second image are transferred onto a first surface of the substrate and a second surface of the substrate, respectively.

17. The method of claim 12, wherein the powder coat is a resin based powder coat that cures to be substantially transparent.

18. The method of claim 13, wherein the powder coat is a resin based powder coat that cures to be substantially transparent and tinted.

19. A method for finishing a substrate, comprising the steps of:

providing a substrate comprising medium density fiberboard;

transferring at least a first image comprising a wood grain onto the substrate using at least one of laser embossing and laser etching;

transferring at least a second image comprising at least one of a graphic, pattern, design, logo, character, text, likeness, and picture onto the substrate using at least one of a laser embossing and laser etching;

preheating the substrate;

electro-static powder coating the substrate with a powder coat;

heating the substrate to cause the powder coat to at least one of gel and flow; and

curing the powder coat.

20. The method of claim 19, wherein the curing step is an ultra violet curing step.

21. The method of claim 19, wherein the curing step is a thermal curing step.

22. The method of claim 19, wherein the preheating step uses both infra red energy and convection.

23. The method of claim 19, further comprising the step of conveying the substrate through the preheating, powder coating and curing steps on a conveyor system.

24. The method of claim 19, wherein the curing step is a combination of at least thermal curing and ultra violet curing.

25. A method for finishing a substrate, comprising the steps of:

providing a substrate comprising medium density fiberboard;

transferring at least a first image comprising a wood grain onto the substrate;

preheating the substrate;

electrostatic powder coating the substrate with a powder coat;

heating the substrate to cause the powder coat to at least one of gel and flow; and

curing the powder coat thereby creating a product with a simulated wood grain finish.