Process for the manufacturing of surface elements with a structured upper surface

• US 6,991,830 B1
• Filed: 11/24/2000
• Issued: 01/31/2006
• Est. Priority Date: 12/23/1999
• Status: Expired due to Term

• Current Assignee: Unilin Nordic AB (Mohawk Industries Incorporated)
• Original Assignee: Pergo Europe AB (Mohawk Industries Incorporated)
• Inventors: Hansson, Krister, Wernersson, Hakan, Lundgren, Johan
• Primary Examiner(s): PARKER, FREDERICK JOHN
• Application Number:
  US09/718,401
• Time in Patent Office: 1,894 Days
• Field of Search: 427/258, 427/259, 427261-263, 427/267, 427/282, 427/287, 427/496, 427/504, 427/508, 427/510, 427/199, 427202-205, 427/466, 427/521, 427/264, 427/265, 523/16
• US Class Current: 427/504
• 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 a decorative surface element, which element comprises a base layer and a decorative upper surface. A wetting repellent lacquer is printed in a predetermined pattern on the decorative upper surface. The wetting repellent lacquer covers only parts of the decorative upper surface. A wear layer of a UV or electron beam curing lacquer is then applied on top of the decorative upper surface which UV or electron beam curing lacquer is repelled from the parts of the surface being covered by the wetting repellent lacquer whereby a surface structure is achieved.

Claims

1. A process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being at least one of a tongue-and a groove, the upper surface comprises a base layer and a decorative upper surface, the process comprising,

i) providing the decorative upper surface with a decor layer, the decor layer comprising a pattern;

ii) printing a wetting repellant lacquer in a predetermined pattern on the decorative upper surface, at least partially matching the pattern on the decor layer, the wetting repellant covering only part of the decorative upper surface, thereafter

iii) applying a wear layer of a UV or electron beam curing lacquer on top of the decorative upper surface, which UV or electron beam curing lacquer is repelled from the part of the surface being covered by the wetting repellant lacquer whereby a surface feature is achieved;

iv) sprinkling abrasion resistant particles, the particles being at least one selected from the group consisting of α

-aluminum oxide, silicone carbide, silicon oxide and diamond, on the surface element;

v) curing the wear layer; and

vi) removing a portion of the particles by applying a high pressure air stream, thereby providing the building panel.

2. A process according to claim 1, wherein said UV or electron beam curing lacquer consists of one selected from the group consisting of an acrylic, epoxy and a maleimide lacquer.

3. A process according to claim 1, wherein the applying step comprises multiple applications of the wear layer with intermediate partial curing between each of the multiple applications.

4. A process according to claim 1, wherein the particles have a hardness greater than the hardness of the cured wear layer and an average particle size in the range of 50 nm–

150 μ

m.

5. A process according to claim 4, wherein the particles comprise scratch resistant particles selected from the group consisting of diamond, silicon oxide, α

-aluminum oxides, silicon carbide and mixtures thereof.

6. A process according to claim 4, wherein a first amount of the particles consist of one selected from the group consisting of silicon oxide, α

-aluminum oxide and silicon carbide, while a smaller amount of the particles consist of diamond.

7. A process according to claim 6, wherein the particles consist of diamond, having an average particle size in the range of 50 nm–

2 μ

m, and are placed close to the upper surface of the wear layer, such that the particles provide the wear layer with abrasion resistance.

8. A process according to claim 1, wherein the wetting repellant lacquer comprises a UV or electron beam curing lacquer and a silicone polymer.

9. A process according to claim 8, wherein the wetting repellant lacquer comprises UV or electron beam curing acrylic, epoxy or a maleimide lacquer.

10. A process according to claim 8, wherein the wetting repellent lacquer is translucent.

11. A process according to claim 8, wherein the wetting repellent lacquer is translucent in at least one part and transparent or opaque in at least one other part.

12. A process according to claim 11, wherein the wetting repellent lacquer comprises a matting agent, whereby the matting agent creates a structure enhancing shadow effect.

13. A process according to claim 11, wherein the wetting repellent lacquer includes a matting agent, whereby the matting agent creates a structure enhancing effect.

14. A process according to claim 8, wherein the wetting repellent lacquer is cured before the step where the wear layer is applied.

15. A process according to claim 1, wherein the decor layer is produced from a digitally stored original, that the digitally stored original is processed in order to achieve a digital structure original whereby a surface structure that matches the decor is achieved through one or more processes selected from the group consisting of printing, embossing, molding, and rolling of at least a portion of the digital structure original.

16. A process according to claim 8, wherein the printing comprises applying the wetting repellent lacquer by means of an ink-jet printer.

17. A process according to claim 1, wherein the base layer consists of a particle board or a fibre board.

18. A process according to claim 1, wherein the base layer comprises a polymer.

19. A process according to claim 1, wherein, the decor layer is formed by a process comprising processing a digitally stored image.

20. A process according to claim 19, wherein the digitally stored image resembles a structure selected from the group consisting of wood and minerals.

21. A process according to claim 19, wherein the processing comprises editing the digitally stored image by at least one selected from the group consisting of digitizing a number of wood grains, scanning a desired pattern, changing color tones, adjusting contrast, dividing the image into smaller images and adding other decorative elements.

22. A process according to claim 19, wherein the digitally stored image comprises dark sections and light sections and the printing comprises depositing the wetting repellent lacquer on the dark sections.

23. A process according to claim 1, wherein the decor layer comprises a wood pattern, comprising one or more selected from the group consisting of knots, cracks, flaws and grains.

24. A process according to claim 23, wherein said printing comprises applying the wetting repellent lacquer in a configuration identical to the pattern in the decor layer.

25. A process according to claim 3, wherein said printing comprises applying the wetting repellent lacquer in a configuration to enhance the pattern.

27. A process according to claim 1, further comprising repeating each of steps iii through vi, at least one time, in sequence, to achieve a plurality of cured layers comprising the abrasion resistant particles.

26. A process for process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising:

applying a primer to a panel to form a primed panel;

providing a decor layer on the primer, the decor layer comprising a pattern;

printing wetting repellant lacquer on parts of the primed panel, matching the decor layer;

placing a layer of UV or electron curing lacquer on the wetting repellent lacquer, whereby the UV or electron beam curing lacquer is repelled from the parts of the primed panel where the wetting repellant lacquer has been printed;

sprinkling abrasion resistant particles on the surface element, the particles being at least one selected from the group consisting of α

-aluminum oxide, silicone carbide, silicon oxide and diamond;

curing the UV or electron curing lacquer; and

removing a portion of the hard particles by applying a high pressure air stream.

37. The process of claim 26, further comprising sprinkling scratch resistant particles on the building panels, the particles being at least one selected from the group consisting of α

-aluminum oxide, silicone carbide, silicon oxide and diamond.

28. A process for process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising process for the manufacturing of a decorative surface element, which element comprises a base layer and a decorative upper surface, the process comprising,

i) selecting a digitized design at a first location;

ii) transmitting the digitized design to a second location, remote from the first location;

iii) providing the decorative upper surface with a decor layer, the decor layer comprising a pattern, the pattern being derived from the digitized design;

iv) printing a wetting repellant lacquer in a predetermined pattern on the decorative surface, at least partially matching the pattern on the decor layer, the wetting repellant covering only part of the decorative surface, and thereafter

v) applying a wear layer of a UV or electron beam curing lacquer on top of the upper surface, which UV or electron beam curing lacquer is repelled from the part of the surface being covered by the wetting repellant lacquer whereby a surface feature is achieved.

29. A process according to claim 28, wherein the transmitting comprises sending the digitized design via a computer network.

30. A process according to claim 29, wherein the computer network is the Internet.

31. A process according to claim 28, wherein the digitized design is selected from a database of selectable designs.

32. A process according to claim 28, further comprising digitizing an image to achieve the design.

33. A process for the manufacturing of decorative surface, the surface being formed from a plurality of building panels, the building panels together forming a decorative surface, each building panel comprising an upper surface having a surface area, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising,

i) selecting a design at a first location, wherein the design has a size larger than the surface area of each surface element;

ii) dividing the design into a plurality of segments, each segment having a surface area corresponding to the surface area of one of the upper surfaces;

iii) providing the upper surfaces with decor layers, the decor layers each comprising one segment of the design, such that when the building panels surface are installed, the design is reproduced across the plurality of building panels.

34. A process according to claim 33, further comprising;

iv) printing a wetting repellant lacquer in a predetermined pattern on the upper surfaces, at least partially matching the segments on the decor layers, the wetting repellant covering only part of the upper surface, and thereafter

v) applying a wear layer of a UV or electron beam curing lacquer on top of the upper surfaces, which UV or electron beam curing lacquer is repelled from the part of the surface being covered by the wetting repellant lacquer whereby a surface feature is achieved.

35. A process according to claim 33, further comprising:

iv) providing each building panel with at least one of a matching line and a unique identification to assist in installation.

36. A process for the manufacturing of a decorative surface, the decorative surface being formed from a plurality of building panels, each building panel comprising an upper surface having a surface area, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising,

i) selecting a digitized design at a first location;

ii) transmitting the digitized design via the Internet to a second location; and

iii) providing the upper surfaces with a decor layer, the decor layer comprising a pattern, the pattern being derived from the digitized design.