PROCESS FOR THE MANUFACTURING OF SURFACE ELEMENTS

• US 20120288689A1
• Filed: 05/09/2012
• Published: 11/15/2012
• Est. Priority Date: 12/23/1999
• Status: Active Grant

• Current Assignee: Unilin Nordic AB (Mohawk Industries Incorporated)
• Original Assignee: Pergo Europe AB (Mohawk Industries Incorporated)
• Inventors: Hansson, Krister, Lundgren, Johan, Wernersson, Hakan
• Granted Patent: US 8,944,543 B2
• Time in Patent Office: Days
• US Class Current: 428/195.1
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2260/02 Composition of the impregnated, bonded or embedded layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/02 Wall papers, wall coverings
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/08 Impregnating
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/00 Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B41J 11/0015 for treating before, during or after printing or for uniform coating or laminating the copy material before or after printing selective coating B41J2/2114
• CPC Class Codes: B41J 2/21 for multi-colour printing
• CPC Class Codes: B41J 3/407 for marking on special material
• CPC Class Codes: B41M 1/26 : Printing on other surfaces than ordinary paper B41M1/40 takes precedence
• CPC Class Codes: B41M 3/00 : Printing processes to produce particular kinds of printed work, e.g. patterns printing apparatus or machines of special type or for particular purposes B41F17/00; special designs or pictures per se B44F; manufacturing printed circuits using printing techniques H05K3/12 ; manufacturing organic semiconductor devices using printing techniques H10K71/13
• CPC Class Codes: B41M 3/006 : Patterns of chemical products used for a specific purpose, e.g. pesticides, perfumes, adhesive patterns; use of microencapsulated material; Printing on smoking articles
• CPC Class Codes: B41M 7/0027 : using protective coatings or layers by lamination or by fusion of the coatings or layers
• 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: B44C 3/02 : Superimposing layers B44C3/005 takes precedence
• CPC Class Codes: B44C 3/08 : Stamping or bending
• CPC Class Codes: B44C 3/085 : stamping B44C3/082 takes precedence
• CPC Class Codes: B44C 5/04 : Ornamental plaques, e.g. decorative panels, decorative veneers
• CPC Class Codes: B44C 5/0446 : bearing graphical information
• CPC Class Codes: B44C 5/0469 : comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
• CPC Class Codes: B44C 5/0476 : with abrasion resistant properties
• CPC Class Codes: B44C 5/0492 : containing wooden elements
• CPC Class Codes: B44D 2/00 : Special techniques in artistic painting or drawing, e.g. oil painting, water painting, pastel painting, relief painting
• CPC Class Codes: B44D 3/003 : Methods or devices for colour determination, selection or synthesis, e.g. use of colour tables
• CPC Class Codes: B44F 1/06 : produced by transmitted light, e.g. transparencies, imitations of glass paintings
• CPC Class Codes: B44F 9/02 : wood grain effects
• CPC Class Codes: B44F 9/04 : of stone surfaces, e.g. marble
• CPC Class Codes: E04B 9/0435 : having connection means at the edges
• CPC Class Codes: E04B 9/045 : being laminated
• CPC Class Codes: E04B 9/32 : Translucent ceilings, i.e. permitting both the transmission and diffusion of light E04B9/303 and E04B9/34 takes precedence; lighting F21
• CPC Class Codes: E04F 13/072 : composed of specially adapted, structured or shaped covering or lining elements
• CPC Class Codes: E04F 13/0871 : having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: E04F 13/16 : of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• CPC Class Codes: E04F 13/18 : of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence
• CPC Class Codes: E04F 15/02 : Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/02038 : characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/105 : of organic plastics with or without reinforcements or filling materials
• CPC Class Codes: E04F 15/107 : composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: E04F 2201/0107 : by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
• CPC Class Codes: E04F 2201/023 : with a continuous tongue or groove
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24364 : with transparent or protective coating
• CPC Class Codes: Y10T 428/24372 : Particulate matter
• CPC Class Codes: Y10T 428/24388 : Silicon containing coating
• CPC Class Codes: Y10T 428/2443 : Sand, clay, or crushed rock or slate
• CPC Class Codes: Y10T 428/24438 : Artificial wood or leather grain surface
• CPC Class Codes: Y10T 428/24455 : Paper
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/24595 : and varying density
• CPC Class Codes: Y10T 428/2462 : with partial filling of valleys on outer surface
• CPC Class Codes: Y10T 428/24653 : Differential nonplanarity at margin
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24876 : Intermediate layer contains particulate material [e.g., pigment, etc.]

Abstract

A process for the manufacturing of surface elements is provided herein. The surface elements can include a decorative upper layer and a supporting core. A supporting core with a desired format is manufactured and provided with an upper side and a lower side. The upper side of the supporting core is provided with a décor, by for example printing, which décor is positioned after a predetermined fixed point on the supporting core. The upper side of the supporting core is provided with a protecting, at least partly translucent, wear layer by for example spray coating, roller coating, curtain coating and immersion coating or by being provided with one or more sheets of a-cellulose impregnated with thermosetting resin or lacquer.

Claims

1. A process for manufacturing a panel, the process comprising:

providing a supporting core with an upper side; and

printing a decor on the upper side of the supporting core using a digital printer, the decor being achieved by digitizing an actual archetype and/or creating the decor in a digital medium.

2. The process according to claim 1, wherein the dé

cor is printed at a resolution of up to 1500 dots per inch (dpi).

3. The process according to claim 1, wherein the digital printer comprises a digital inkjet printer.

4. The process according to claim 1, wherein the printing comprises directly printing the decor on the upper side of the supporting core.

5. A panel comprising:

a supporting core with an upper side;

a decorative layer on the upper side of the supporting core comprising a decor that comprises a digital image printed on the upper side of the supporting core.

6. The panel according to claim 5, wherein the decor comprises a digital image directly printed on the upper side of the supporting core.

7. The panel according to claim 5, wherein the decor comprises a resolution of up to 1500 dots per inch (dpi).

8. The panel according to claim 5, wherein the digital image comprises at least one of a digitized archetype or an image from a digital medium.

9. The panel according to claim 5, wherein the digital image is printed on the upper side of the supporting core using a digital inkjet printer.

10. A surface element comprising:

a supporting core with an upper side;

a decorative layer on the upper side of the supporting core comprising a dé

cor that comprises a digital image printed on the upper side of the supporting core; and

wherein the surface element forms at least one of a floor element configured to be joined with corresponding floor elements to form a floor covering, a wall element configured to be joined with corresponding wall elements to form a wall covering, or ceiling element configured to be joined with corresponding ceiling elements to form a ceiling.

11. The surface element according to claim 10, wherein the decor comprises a digital image directly printed on the upper side of the supporting core.

12. The surface element according to claim 10, wherein the decor comprises a resolution of up to 1500 dots per inch (dpi).

13. The surface element according to claim 10, wherein the digital image comprises at least one of a digitized archetype or an image from a digital medium.

14. The surface element according to claim 10, wherein the digital image is printed on the upper side of the supporting core using a digital inkjet printer.

15. A process for manufacturing a surface element, the process comprising:

providing a supporting core with an upper side; and

printing a decor on the upper side of the supporting core using a digital printer, the decor being a digital image; and

wherein the surface element forms at least one of a floor element configured to be joined with corresponding floor elements to form a floor covering, a wall element configured to be joined with corresponding wall elements to form a wall covering, or ceiling element configured to be joined with corresponding ceiling elements to form a ceiling.

16. The process according to claim 15, wherein the digital image is achieved by digitizing an actual archetype and/or creating the decor in a digital medium.

17. The process according to claim 16, wherein the dé

cor is printed at a resolution of up to 1500 dots per inch (dpi).

18. The process according to claim 16, wherein the digital printer comprises a digital inkjet printer.

19. The process according to claim 16, wherein the printing comprises directly printing the decor on the upper side of the supporting core.