Process for the manufacturing of surface elements

• US 6,565,919 B1
• Filed: 11/24/2000
• Issued: 05/20/2003
• 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, F
• Application Number:
  US09/718,398
• Time in Patent Office: 907 Days
• Field of Search: 427/258, 427/262, 427/264, 427/267, 427/270, 427/277, 427/278, 427/204, 427/205, 427/203, 427/420, 427/421, 427/428, 427/430, 427/440, 428/206, 428/208
• US Class Current: 427/203
• 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 (1) which comprises a decorative upper layer (2) and a supporting core (5). A supporting core (5) with a desired format is manufactured and provided with an upper side (1′) and a lower side (4). The upper side (1′) of the supporting core (5) is provided with a décor , by for example printing, which décor (2′) is positioned after a predetermined fixed point on the supporting core (5). The upper side (1′) of the supporting core (5) is provided with a protecting, at least partly translucent, wear layer (2″) by for example spray coating, roller coating, curtain coating and immersion coating or by being provided with one or more sheets of α-cellulose impregnated with thermosetting resin or lacquer.

Claims

1. A process for the manufacturing of surface elements which surface elements comprise a decorative upper layer and a supporting core;

said process comprising;

i) providing a supporting core with an upper side;

ii) providing the upper side of the supporting core with a dé

cor, which dé

cor is achieved by at last one of digitizing an actual archetype and at least partly creating said dé

cor in a digital medium, which dé

cor is positioned after a predetermined fixing point on the supporting core,

iii) protecting the upper side of the supporting core with an at least partly translucent, wear layer,

iv) enhancing the dé

cor by accurately applying a surface structured matrix against the wear layer utilizing the predetermined fixing point to create a surface structure on the wear layer.

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

cor is achieved by digitization of an actual archetype or by partly or completely being created in a digital media, which digitized dé

cor is stored digitally in order to be used as a control function and original when printing the dé

cor.

3. A process according to claim 2, wherein at least parts of the digitized dé

cor is used, together with support programs for controlling further steps in the manufacturing procedure.

4. The process according to claim 3, wherein said further steps in the manufacturing procedure include at least one of identification marking, packaging, lacquering, surface embossing, storage logistics, delivery logistics, and assembly instructions.

5. The process according to claim 2, further comprising forming the dé

cor by using controlled programs in combination with the digitized dé

cor.

6. A process according to claim 1, wherein the supporting core is manufactured in the desired end user format and provided with edges intended for joining before applying the dé

cor and the wear layer.

7. A process according to claim 1, wherein the supporting core is at least one of selected from the group consisting of a particle board and a fibre board.

8. A process according to claim 1, wherein at least parts of the supporting core comprise a polymer.

9. A process according to claim 8, wherein the supporting core comprises a polymer which also contains a filler in the form of a particle or fibre of organic or inorganic material.

10. The process according to claim 8, wherein said polymer comprises a polyurethane or a polyolefin.

11. The process according to claim 10, wherein said polyolefin is at least one selected from the group consisting of polyethylene, polypropylene and polybutylene.

12. A process according to claim 1, wherein the translucent wear layer consists of a UV curing or electron beam curing resin or lacquer.

13. A process according to claim 12, further comprising applying the wear layer in several steps with intermediate curing, of which the last applying comprising a curing step which is a complete curing while the intermediate curing step(s) are only partial curing step(s).

14. A process according to claim 12, wherein the wear layer also comprises hard particles with an average particle size in the range 50 nm-150 μ

m.

15. A process according to claim 14, wherein an upper portion of the wear layer is provided with hard particles in the range 50 nm-30 μ

m, while an inner portion of the wear layer is provided with hard particles in the range 10 μ

m-150 μ

m.

16. A process according to claim 15, wherein the hard particles are at least one selected from the group consisting of silicon oxide, silicon carbide, α

-aluminium oxide and diamond.

17. The process according to claim 15, wherein the particles in the upper portion of the wear layer are in the range of 50 nm-10 μ

m, while the particles in the inner portion of the wear layer are in the range 30 μ

m-150 μ

m.

18. A process according to claim 14, wherein the hard particles are at least one selected from the group consisting of silicon oxide, silicon carbide and α

-aluminium oxide.

19. The process according to claim 12, in which said resin or lacquer is one selected from the group consisting of acrylic, epoxy and maleimide.

20. A process according to claim 1, wherein the translucent wear layer consists of at least one sheet of α

-cellulose impregnated with melamine-formaldehyde resin.

21. A process according to claim 20, wherein the wear layer is joined with the supporting core through heat and pressure, whereby the resin cures.

22. A process according to claim 20, wherein the wear layer also comprises hard particles with an average particle size in the range 50 nm-150 μ

m.

23. A process according to claim 22, wherein an upper portion of the wear layer is provided with hard particles in the range 50 nm-30 μ

m, while an inner portion of the wear layer is provided with hard particles in the range 10 μ

m-150 μ

m.

24. A process according to claim 23, wherein the hard particles are at least one selected from the group consisting of silicon oxide, silicon carbide, α

-aluminium oxide and diamond.

25. A process according to claim 22, wherein the hard particles are at least one selected from the group consisting of silicon oxide, silicon carbide and α

-aluminium oxide.

26. The process according to claim 23, wherein the particles in the upper portion of the wear layer are in the range of 50 nm-10 μ

m, while the particles in the inner portion of the wear layer are in the range of 30 μ

m-150 μ

m.

27. A process according to claim 1, wherein the dé

cor on the surface elements is constituted by a number of dé

cor segments with intermediate borders, which borders, on at least two opposite edges of a surface element coincide with borders on intended adjoining floor elements.

28. A process according to claim 1, wherein said at least one surface structured matrix forms at least one surface structure segment and is positioned on the decorative side of the surface element during the step in the process where the wear layer is applied on the surface element and is pressed towards the wear layer whereby the wear layer receives a surface with a structure that enhances the realistic impression of the dé

cor.

29. A process according to claim 28, wherein at least one matrix forms the structured surface of at least one roller whereby the surface element is passed between the structured surface roller and a matching counter stay under continuous or discontinuous pressure between the rollers and the counter stay.

30. A process according to claim 29, wherein the roller equipped with two or more matrixes has a circumference adapted to a repetition distance in the variation of direction in the dé

cor.

31. A process according to any of the claims 28, wherein a specially characteristic dé

cor segments is visually simulated in the dé

cor is stored as digital data, that said data is used for guiding automated engraving or pressing tools when providing said characteristic dé

cor segments with a suitable surface structure, and that said engraving tool or pressing tool is synchronised via the predetermined fixing point on the surface element.

32. The process according to claim 31, wherein the specially characteristic dé

cor segments are at least one selected from the group consisting of borderlines between simulated slabs, bars or blocks;

knots, cracks, flaws and grain.

33. A process according to claim 1, further comprising providing at least two surface structured matrixes, which each matrix forms one surface structure segment, which segments are independent from each other concerning structure, and that said surface structure segments are intended to coincide with corresponding pattern segments in the decor, positioning said surface structured matrices on the decorative side of the surface element during the steps in the process where the wear layer is provided, and pressing the matrices toward the wear layer whereby the wear layer receives a surface structure corresponding to different pattern segments in the dé

cor.

34. A process according to claim 33, wherein one or more matrixes forms the structured surface on one or more press belts, whereby the surface element is passed between the press belts and counter stays, with the decorative side facing the press belts, during continuous or discontinuous pressure between the press belts and counter stays.

35. A process according to claim 33, wherein at least one matrix forms the structured surface on at least one static moulds which is pressed towards the decorative surface of the surface element.

36. The process according to claim 1, wherein the protection of the upper side of the supporting core is achieved by at least one coating step selected from the group consisting of spray coating, roller coating, curtain coating, and immersion coating.

37. The process according to claim 1, wherein protecting of the upper side of the supporting core is achieved by providing at least one sheet of α

-cellulose impregnated with thermosetting resin or lacquer as the at least partly translucent, wear layer.

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

cor is formed by printing.

39. The process according to claim 1, wherein said core is formed of fiberboard.