System for producing a substrate having a decorative design

Abstract

The invention relates to a system for producing a substrate (1) with a decorative design (3), such as an image and / or a relief, comprising a feed device (10; 90), a digital printing device (5, 40) for printing the decorative design (3) on a foil (2), and a covering device (30; 50, 51) for covering the substrate (1) with the foil (2). The system is configured for the digital printing device (5, 40) to print the foil (2) after the foil (2) is supplied by the feed device (10; 90) and before the substrate (1) is covered by the covering device (30; 50, 51).

Description

Technical Field

[0001] The present invention relates to a system for producing substrates, such as panels or profiles, incorporating a decorative design, such as an image and / or a relief, as a surface finish adapted to the particularities of the substrate.

[0002] The invention relates in particular to covering substrates with foil or layer materials. The invention is particularly suitable for use in construction and furniture products such as furniture panels, doors and flooring, door and window frame profiles, etc. Background Art

[0003] Currently, systems for applying decorative designs formed by images and / or reliefs provided on a foil covering a substrate are known. In these systems, the foil is provided with a decorative design incorporated therein, and then panels or profiles are covered with the foil and bonded to one another by means of an adhesive applied between the foil and the substrate.

[0004] Today's requirements increasingly require the continuous production of substrates with sparsely repeated decorative designs. This necessitates a change in the foil feed or continuous foil feed reel in order to replace the printed foil with the respective desired decorative design and to obtain a variety of decorative designs produced by the same system.

[0005] An exemplary method for manufacturing a printed product can be found in EP 2 329 954 A1 .

[0006] The present invention aims to provide a system for producing substrates with decorative designs, which system makes it possible to obtain substrates with various decorative designs in a versatile manner. Summary of the Invention

[0007] In order to solve the above objects, in addition to providing additional advantages that will be mentioned below, the present invention provides a system for producing a substrate with a decorative design, such as an image and / or a relief, comprising a feeding device for feeding a foil, a digital printing device, in particular an inkjet printing device, of the decorative design on the foil, and a covering device for covering the substrate with the foil.

[0008] According to the present invention, the system is configured to print the foil with a digital printing device after the foil is fed to the feed device and before the substrate is covered with the covering device. The incorporation of the digital printing device in the system enables substrates with various decorative designs to be obtained in a universal manner, thereby allowing the desired printing to be selected for each foil covering the corresponding substrate.

[0009] In this way, the substrate can be given any desired appearance or even a change of decorative design without having to change the feed reel or the foil. Likewise, it enables various surfaces of the substrate to be covered (completely or partially), such as the top, the lateral edges, the bottom, even complex surfaces, etc., with different decorative designs for different selected surface areas.

[0010] This ability to provide different decorative designs on the same foil increases the flexibility in performing the covering, for example, being able to provide foils with different decorative designs for different sides of the substrate, particularly the top and edges of the panel, or to provide continuity of the decorative design between different sides.

[0011] The feeding device for feeding foil according to the invention can be configured for feeding foil continuously, for example by means of a foil feeding reel. Alternatively, the feeding device for feeding foil can be configured for feeding foil discontinuously, for example using a foil-by-foil feeding device.

[0012] It is contemplated that the system according to the present invention includes a processing unit functionally connected to the digital printing device, such that the processing unit is configured to print different decorative designs for different substrates and / or foils. The processing unit is configured to print different decorative designs based on physical characteristics of the substrate and / or foil, such as size, shape, material, surface roughness, etc. Thus, it is possible to provide different decorative designs for different substrates in a flexible manner and in real time.

[0013] According to the present invention, it is envisaged that physical characteristics of the substrate and / or foil can be detected, for example, by scanning or sensing the substrate and / or foil or by instructions received in the processing unit. To this end, the system can incorporate a scanner or sensor, for example, to directly detect physical characteristics of the substrate and / or foil or to detect markings or identifications of the substrate and / or foil.

[0014] The system according to the invention may further comprise an application device for applying adhesive, so as to apply adhesive to the substrate and / or foil so that the substrate and / or foil are bonded together by the adhesive after covering. The application device for applying adhesive may be, for example, a lip, a roller, spraying, digital printing, in particular inkjet, etc.

[0015] Alternatively or additionally, it is also conceivable that the foil can be supplied at least partially pre-glued.

[0016] Preferably, it is envisaged that the processing unit is functionally connected to the application device for applying the adhesive and is thus configured for applying different amounts of adhesive depending on the physical characteristics of the substrate and / or foil, such as size, shape, material, surface roughness, etc. This enables a more flexible production of substrates with decorative designs depending on different physical characteristics of the substrate and / or foil and thus of the decorative design.

[0017] According to the invention, the covering device can be configured for shaping the foil on the substrate surface so that the foil adapts to the shape of the substrate.

[0018] The present invention also contemplates that the system according to the invention may include a first digital printing device for an image and a second digital printing device for a relief, the system being configured such that the first device and the second device print the respective image and relief synchronously with each other. Thus, a relief corresponding to the image may be obtained, enabling, for example, the texture or tactile surface of a natural material such as wood or stone to be simulated or replicated. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The following drawings have been included as part of the explanation of at least one practical embodiment of the invention.

[0020] Figure 1 A schematic diagram showing a first embodiment of a system according to the invention is shown.

[0021] Figure 2 A schematic diagram of a second embodiment of the system according to the invention is shown, wherein, unlike the first embodiment, covering the substrate with the foil comprises shaping the foil.

[0022] Figure 3 A schematic diagram is shown of a first variant of the first embodiment of the system according to the invention, wherein the adhesive application is effected by digital inkjet printing instead of by a lip.

[0023] Figure 4 A schematic diagram is shown of a second variant of the first embodiment of the system according to the invention, wherein adhesive application is effected by means of a roller instead of by means of a lip.

[0024] Figure 5 A schematic diagram of a third embodiment of the system according to the invention is shown, wherein, unlike the first embodiment, the adhesive application is carried out both to the foil and to the substrate.

[0025] Figure 6 A schematic diagram shows a first variant of a third embodiment of the system according to the invention, wherein the application of adhesive to the foil is effected by a lip rather than by digital inkjet printing.

[0026] Figure 7A schematic diagram shows a second variant of the third embodiment of the system according to the invention, wherein the application of adhesive to the foil is effected by a lip rather than by digital inkjet printing and the application of adhesive to the substrate is effected by a roller rather than by digital inkjet printing.

[0027] Figure 8 A schematic diagram shows a fourth embodiment of the system according to the invention, in which, unlike the previous embodiments, the foil feeding is performed discontinuously, that is to say foil by foil and not via a continuous feed reel.

[0028] Figure 9 A schematic diagram illustrating sequential steps of an exemplary embodiment of a process for manufacturing a substrate having a decorative design that can be performed by a system according to the present invention. DETAILED DESCRIPTION

[0029] The system uses a substrate (1) as a base product, which is covered with a foil (2) onto which a personalized decorative design is applied "in situ" in a continuous process using a digital inkjet printing device (5, 40). Thus, a substrate (1) covered with printed foil (2) is obtained, which is provided with a surface finish having a decorative design (3). Thus, depending on the decorative design (3) of the covering foil used, the substrate (1), such as a panel or profile, can be given any desired appearance.

[0030] The substrate (1) can be made of various materials, such as wood derivatives (particleboard, medium density fiberboard "MDF", high density fiberboard "HDF" or plywood), plastic materials (PVC), cellulose-based materials (paper or cardboard), metal materials, etc. The foil (2) can be made of paper, PVC, HPL, CPL, etc.

[0031] The digital inkjet printing device (5, 40) comprises at least one digital inkjet print head (5) and a digital printing curing or drying device (40) for curing and / or drying the printed ink producing the decorative design.

[0032] The feeding device (10; 90) for feeding the foil (2) can be continuous (10) or discontinuous (90). Figures 1 to 7 In an embodiment of the present invention, the foil (2) is continuously fed from a feed reel (10) and thereby guided to the covering portion of the substrate (1) by at least one guide roller (20, 60). Figure 8 In the embodiment of the present invention, the foils (2) are fed discontinuously from the foil stack (90), ie, foil by foil.

[0033] It is envisaged that, for applying the adhesive (4), the system comprises means for applying the adhesive (6; 7, 70; 8, 9; 11, 80; 12, 13), which is configured to apply the adhesive (4) to the substrates (1) and / or foils (2) to be bonded together after covering. The application of the adhesive (4) can be carried out before or after the digital printing. In a variant of the system shown in the figures, the application of the adhesive (4) is carried out after the application of the decorative design (3). However, according to the invention, it is also envisaged that, alternatively or in addition, it can be carried out before the application of the decorative design.

[0034] A covering device (30; 50, 51) for covering a substrate (1) with a foil (2) comprises a pressure roller (30) for spreading the foil (2) on the surface of the substrate (1) so that the foil (2) covers the surface of the substrate (1), in particular a flat surface. Figure 2 In an embodiment of the present invention, the covering device (30; 50, 51) further comprises a forming roller system (50, 51) for forming the foil (2) on the surface of the substrate (1), in this case so that the foil (2) is folded over the lateral edges of the substrate (1), but it can be configured so that the foil (2) covers surfaces of the substrate (1) that are inclined relative to each other or complex surfaces. By applying pressure with the covering device (30; 50, 51), adhesion between the substrate (1) and the foil (2) is achieved.

[0035] like Figure 1 As shown, a continuous foil (2) is fed from a feed reel (10) by guide rollers (20), a decorative design (3) is executed on the foil (2) by a digital inkjet print head (5), and then cured or dried by a digital print curing or drying device (40).

[0036] Adhesive (4) is applied to the foil (2) with the decorative design (3) by means of an adhesive applicator lip (6) and once the adhesive (4) has been applied, the printed foil (2) which has been coated with glue is attached to the substrate (1) by pressing the foil (2) against the substrate (1) with the aid of a pressure roller (30), thereby covering it and thus obtaining a completely homogeneous final product.

[0037] Figure 1 The embodiment shown is not limiting since, as can be seen from the different figures, many variations exist depending on the elements used and their placement in the system.

[0038] Therefore, in Figure 2 In the exemplary embodiment of the present invention, the above is followed by a forming stage by means of a forming roller system (50, 51). Thus, the foil (2) covers the substrate (1), adapting to the shape of the substrate (1) so that both the front surface and the edges are covered by the foil (2).

[0039] The forming roller system (50, 51) consists of a system of longitudinal pressure tools (usually wheels with different characteristics) that form, post-form or profile the foil (2) on the substrate (1) in the direction of advance towards the substrate to be covered. Other strategically positioned elements can be used to adhere the foil (2) to the substrate, adapting it to the shape of the substrate (1) until it obtains its final shape at the end of the process, thus becoming integrated with the substrate (1).

[0040] Similarly, in Figure 3 In an embodiment of the invention, after digital inkjet printing, adhesive (4) is applied to the foil (2) after the foil (2) has been guided by two continuous foil guide rollers (20 and 60). In this variant, the application of the adhesive (4) is performed by means of an adhesive digital inkjet print head (7), with subsequent curing or drying being performed by means of an adhesive curing or drying device (70) before the application of a rotating pressure roller (30) in the direction of advancement towards the substrate (1).

[0041] also, Figure 4 The embodiment follows the same process, but the adhesive (4) is applied to the foil (2) by an applicator roller (8) in cooperation with an adhesive dosing roller (9) for dosing a certain amount of adhesive (4) on the applicator roller (8) by relative rotation and movement between the applicator roller (8) and the dosing roller (9).

[0042] Likewise, in Figures 5 to 7 In the embodiment of the system shown, the adhesive (4) is applied to the foil (2) and / or substrate (1) using a variation on the application of the adhesive (4) by a step of digital printing of the decorative design (3) by a digital inkjet print head (5) followed by subsequent curing or drying using a digital print curing or drying device (40). Figure 5 In the embodiment of the present invention, the adhesive (4) is applied to the foil (2) by means of a digital inkjet print head (7) and also to the substrate (1) by means of a digital inkjet print head (11), and in both cases is subsequently cured with an adhesive curing or drying device (70; 80) before applying a pressure roller (30).

[0043] and Figure 5 Different, in Figure 6 In the embodiment of the present invention, the adhesive (4) is applied to the foil (2) by means of the lip (6) without undergoing subsequent curing, and once the adhesive (4) has been applied, it is pressed against the substrate (1) by means of a pressure roller (30). Figure 7 Shown with Figure 6 A different embodiment of the present invention, wherein the adhesive (4) is applied to the substrate (1) by an applicator roller (12) cooperating with a dosing roller (13).

[0044] Figure 8 Represents a process wherein feed material or foil (2) is supplied discontinuously from a foil stack (90) and only adhesive (4) is applied to a substrate (1) by a digital inkjet print head (7) followed by subsequent curing with an adhesive curing or drying device (70).

[0045] As adhesive curing or drying device (40) or digital printing device (70, 80), for example, electromagnetic radiation, UV, IR or electric lamps or drying by hot air can be used.

[0046] According to the invention, the system may comprise supplementary means for preparing the substrate (1) and / or the foil (2), such as means for priming the substrate (1) and / or the foil (2), a protective layer for the foil (2), a base layer for embossing the foil (2), means for removing material from a mixture of droplets ejected by inkjet in order to emboss the foil (2), etc. Figure 9 The following steps illustrate a possible process that can be performed using the system according to the present invention:

[0047] a) Apply primer to foil.

[0048] b) Curing the primer.

[0049] c) Application of decorative designs by inkjet.

[0050] d) Curing or semi-curing printed products.

[0051] e) Applying a protective layer to the printed layer.

[0052] f) Cured or semi-cured protective layer.

[0053] g) Applying a base layer of liquid material in which the embossing is to take place.

[0054] h) ejecting material droplets by inkjet for mixing with the liquid material layer.

[0055] I) Curing process of the mixture and the remaining materials.

[0056] j) Removal of mixed material by mechanical means.

[0057] k) Applying a layer of finishing material.

[0058] l) Curing the finishing layer.

[0059] It is also possible to use a substrate (1) and / or foil (2) that has already been prepared to receive the decorative design (3) and / or the adhesive (4), so that, for example, no primer needs to be applied. It is also possible to have a pre-glued foil (2), which will prevent the adhesive (4) from being applied to the foil (2) during the process.

[0060] The system can advantageously be implemented to replicate different decorative designs on a foil (2) for covering a substrate (1) in a continuous process, or without changing the reel (10) or sheet (90).

Claims

1. A system for producing in a continuous manner different substrates (1) having different physical characteristics with different decorative designs (3), said system comprising - a feeding device (10; 90) for feeding the foil (2), - a digital printing device (5, 40) for printing the decorative design (3) on the foil (2), and - covering means for covering said substrate (1) with said foil (2), The system is configured to print the foil (2) with the digital printing device (5, 40) after feeding the foil (2) with the feeding device (10; 90) and before covering the substrate (1) with the covering device. It is characterized in that The system comprises a processing unit functionally connected to the digital printing device (5, 40), wherein the processing unit is configured for printing different decorative designs (3) for different substrates (1) and foils (2) according to the physical characteristics of the substrates (1) and foils (2) so that various surfaces of the substrates can be covered with foils having different decorative designs for different selected surface areas of the substrates or different decorative designs can be imparted between different surfaces of the substrate in a continuous manner, The system further comprises a scanner or a sensor for directly detecting physical characteristics of different substrates and the foil material so as to provide the characteristics of the substrate and the foil material to the processing unit in real time, and The covering device comprises a pressure roller (30) for pressing the foil (2) coated with glue against the substrate (1); and a forming roller system (50, 51) for forming, folding or profiling the foil (2) on the surface of the substrate (1) after the pressure roller (30) for covering the different selected surface areas of different substrates (1).

2. The system according to claim 1, wherein: It comprises an application device (6; 7, 70; 8, 9; 11, 80; 12, 13) for applying adhesive, which is configured to apply adhesive (4) on the substrate (1) and / or the foil (2) so that the substrate (1) and / or the foil (2) are bonded together by the adhesive (4) after covering.

3. The system according to claim 2, wherein: The processing unit is functionally connected to the application device (6; 7, 70; 8, 9; 11, 80; 12, 13) for applying adhesive, and is configured to apply different amounts of adhesive (4) depending on the physical characteristics of the substrate (1) and / or the foil (2).

4. System according to one of claims 1 to 3, wherein The digital printing device (5, 40) of the decorative design (3) comprises a first digital printing device for an image and a second digital printing device for a relief, wherein the system is configured such that the first device and the second device print the respective image and relief synchronously with each other.

5. System according to one of claims 1 to 3, wherein The different decorative designs can be images and / or reliefs.

6. System according to one of claims 1 to 3, wherein The different selected surface areas can be the top surface, side surface, bottom surface or complex surface of the substrate.

Images