Large-breadth synchronous embossing process

Abstract

The present disclosure relates to a method for manufacturing a panel (1), in particular a wallboard, ceiling, furniture or floor panel, by a synchronous embossing process, comprising the steps of: providing a carrier (10); providing decorative paper (20) with a decorative pattern (21); providing a pressing device with an embossing structure; wherein, in the production of a decorative paper having a decorative pattern and / or a pressing device having an embossed structure, a dimensional change of the decorative paper and / or the pressing device during the production of the sheet material is taken into account.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a board, in particular a method for manufacturing a laminate, a wallboard, a ceiling, a furniture or a floorboard. The present invention further relates to a correspondingly manufactured board and laminate. BACKGROUND

[0002] There are a wide variety of materials available for the production of boards, such as wallboards, ceilings, furniture and floorboards. Furthermore, there are a wide variety of manufacturing methods for boards. Such boards have a variety of different properties. By way of example, these properties include environmental friendliness (e.g. recyclability), haptics, appearance and / or durability (e.g. fire resistance, moisture resistance and / or scratch resistance).

[0003] In particular in the field of boards having a visible surface, which surface comprises a contact surface, there is a continuous need to improve the properties of the boards and / or the corresponding manufacturing methods: these manufacturing methods should be able to provide visually appealing boards, boards with better haptics, while also providing boards with durability.

[0004] In the above-mentioned field of technology for visible surfaces, known boards include laminates, which are relatively inexpensive and easy to handle. Typically, such boards comprise a carrier made of medium density fiberboard (MDF) or high density fiberboard (HDF) material, which allows for heat recycling. In the above-mentioned field of technology for visible surfaces, known methods include applying a decorative layer to the carrier during the manufacturing process to provide visually appealing boards.

[0005] In current practice, decorative boards are typically achieved by applying a decorative print layer to the board by means of gravure printing.

[0006] Conventional gravure printing methods for boards, in particular for wood-based floorboards, typically employ a plurality of engraved cylinders to achieve embossing and to engrave an image on the wood. For this purpose, the image is engraved onto the gravure cylinder before embossing takes place.

[0007] The above-mentioned conventional methods have a number of disadvantages.

[0008] For example, depending on the diameter of the gravure cylinder used for engraving, the printed pattern is repeated on the board. In particular, it must be ensured that the pattern forms a continuous closed loop on the gravure cylinder to avoid discontinuous printing on the wood. This repetition of the pattern leads to an unnatural appearance. The length of the pattern without repetition can be increased by increasing the diameter of the gravure cylinder, but this leads to increased costs.

[0009] For example, when using a gravure cylinder with a circumference of 2100 mm and matching a board width of 2070 mm, a maximum unique pattern area of 4.31 m2can be formed; when using a gravure cylinder with a circumference of 1300 mm and matching a board width of 2070 mm, a maximum unique pattern area of only 2.69 m2can be formed.

[0010] Furthermore, although the prior art has attempted to synchronize the embossed structure of the board with the printed pattern, further improvements are still required, since the synchronization effect has not been satisfactory so far.

[0011] In view of the above-mentioned drawbacks, it is of great interest to provide an improved board as well as an improved method for manufacturing a board.

[0012] It is therefore an object of the present invention to at least partially overcome the above-mentioned drawbacks. In particular, it is an object of the present invention to provide a board which is attractive as a whole and visually appealing. The synchronization of the embossed structure with the decorative pattern should be further improved. The board should also have a tactilely comfortable texture. Furthermore, a corresponding method for manufacturing such a board should be provided. The manufacturing method should be simplified and cost-effective. SUMMARY

[0013] This object is at least partially achieved by the subject matter of the independent claims. Further aspects of the present disclosure are defined by the dependent claims.

[0014] Since the method for manufacturing a board, the board, the system for manufacturing a board and the method for manufacturing a pressing device in a synchronized embossing process all relate to a board according to the present disclosure, it is to be understood that advantages and / or features related to any of them, even if not explicitly stated, can apply to the others as well, and vice versa.

[0015] Method In one aspect, the object is achieved by a method for manufacturing a board, in particular a wallboard, a ceiling, a furniture or a floorboard, by a synchronized embossing process, the method comprising the steps of: providing a carrier board; providing a decorative paper having a decorative pattern; and providing a pressing device having an embossed structure; wherein, when manufacturing the decorative paper having a decorative pattern and / or the pressing device having an embossed structure, dimensional changes of the decorative paper and / or the pressing device during the board manufacturing process are taken into account.

[0016] The method has the advantage that a better synchronization between the decorative pattern and the embossed structure on the carrier plate can be achieved (i.e. the embossing and the pattern are precisely aligned). In particular, the printing and embossing are synchronized, thereby providing a board material that is visually better and more attractive. This can attract the interest of a consumer. In particular, the board material can simulate a realistic look in a better way. For example, the decorative pattern can simulate natural wood or the like, whereas according to the present disclosure, the pattern is copied more precisely. Generally, the prior art does not take into account dimensional changes, which leads to a poor optical effect, because the embossed structure on the carrier plate does not match the decorative pattern. The inventors have found a way to overcome this drawback.

[0017] The "dimensional change" can refer to any kind of elongation, shrinkage, expansion or the like. The dimensional change can result from a change in the conditions of the various heat, pressure, impregnation steps or the like.

[0018] The term "taking into account" (which can mean "based on", "accounted for") is to be understood as that measures have been taken to at least partially compensate for the dimensional change. In particular, the dimensional change of the decorative paper and the pressing device can be different, whereas the inventors have found a way to find an optimal balance to match the two dimensional changes.

[0019] It is to be understood that during the synchronized embossing process, the dimensional change of the decorative paper and / or the pressing device is taken into account when manufacturing the pressing device and the decorative paper. For example, the dimensional change data of the decorative paper can be obtained by a trial run when printing the decorative pattern on the decorative paper (e.g. due to the expansion of the paper during the impregnation process or the like). This information can be used to scale the decorative pattern accordingly to compensate for any dimensional change, as further described herein. It is to be understood that when implementing the method, the provided decorative paper can already contain the scaled decorative pattern. Furthermore, the dimensional change data of the embossed structure of the pressing device (e.g. due to heat and / or pressure) can also be obtained by a trial run. This information can be used to scale the pressing device. It is to be understood that when implementing the method, the provided pressing device can already be scaled.

[0020] The "synchronized embossing process" can be understood as a process to provide a texture, an embossed structure or the like on a carrier plate, which texture or structure follows the decorative pattern of a decorative paper. This can improve the realistic look, thereby achieving the appearance and texture of natural wood, stone or the like. In this sense, it is to be understood that the synchronized embossing process comprises, for example, applying the decorative paper to the carrier plate while embossing the carrier plate using the embossed structure to form an embossed structure on the main surface of the carrier plate that substantially matches the decorative pattern. The embossed structure can be provided, for example, by a veneer press (which can comprise a press plate).

[0021] The embossed structure on the carrier plate can have a three-dimensional shape, i.e. the embossed structure has an identifiable extension in at least three spatial directions.

[0022] Once the decor paper is provided, it can be used directly in the simultaneous embossing process. Alternatively, it can also be wound into a roll and / or stored for a certain period of time before being used in the simultaneous embossing process.

[0023] Preferably, the decor paper with the decor pattern is made by scaling the size of the decor pattern by the one or more first scaling values using a computer.

[0024] This has the advantage that the dimensional changes of the decor paper can be taken into account in a better way. For example, historical data (e.g. past test data) and / or current test data can be used to improve the consideration of the dimensional changes. This helps to better match the embossing structure with the decor pattern on the carrier. The one or more first scaling values can be integer or floating point numbers. The one or more first scaling values can be stored in a non-transitory computer readable medium, e.g. a computer memory, before being applied.

[0025] For example, an image used as the decor pattern can be scaled using the one or more first scaling values. This can be performed by scaling the image before applying the decor pattern to the paper to form the decor paper.

[0026] Preferably, the method comprises impregnating the decor paper, wherein the one or more first scaling values are based at least partly on the dimensional changes of the decor paper during the impregnation.

[0027] The swelling of the decor paper during the impregnation can be quite significant. Therefore, it is advantageous to take this into account by providing the one or more first scaling values accordingly.

[0028] Preferably, the one or more first scaling values vary locally with respect to the decor paper.

[0029] The dimensional changes (e.g. swelling) of the decor paper can differ depending on the location on the decor paper. For example, in the central region of the decor paper, the swelling can be larger than at the outermost edges of the paper. Therefore, it is advantageous for the one or more first scaling values to vary locally in order to achieve a better synchronization in the simultaneous embossing process.

[0030] Preferably, the one or more first scaling values are selected based on a predetermined functional relationship (preferably a swelling curve) and based on the properties of the paper and / or the impregnation conditions.

[0031] This further helps to achieve a better synchronization. The swelling curve can be based on various properties of the paper (e.g. grammage, thickness, etc.) and / or the impregnation conditions (e.g. amount of resin, etc.) to achieve an optimal simultaneous embossing process. This helps to create a more natural looking panel appearance.

[0032] Preferably, the one or more first scaling values are in the range of 0.9 to 1.1, preferably in the range of 0.95 to 1.05, more preferably in the range of 0.98 to 1.02, more preferably in the range of 0.99 to 1.01, more preferably in the range of 0.994 to 1.006, more preferably in the range of 0.996 to 1.004, most preferably in the range of 0.998 to 1.002.

[0033] The one or more first scaling values are chosen to better compensate for any dimensional changes. The one or more first scaling values can also be larger or smaller depending on the specific situation.

[0034] Preferably, the dimensions of the pressing device are chosen based on one or more second scaling values, which are based at least partly on the thermal expansion of the pressing device in the simultaneous embossing process.

[0035] An advantage of this approach is that dimensional changes of the pressing device can be taken into account more precisely. For example, the one or more second scaling values can be determined using historical data, or they can be predicted using a model, such as a simulation model. A large part of the dimensional changes of the pressing device can be caused by the temperature increase. Therefore, it is advantageous to use information on the thermal expansion in the simultaneous embossing process to determine the one or more second scaling values. In this way, the pressing device is manufactured better. This contributes to a better matching of the embossing structure and the decorative pattern on the carrier plate.

[0036] Preferably, the one or more second scaling values comprise a length scaling value for the length of the pressing device and a width scaling value for the width.

[0037] Scaling the length and / or the width of the pressing device can be easier to implement. For example, when using a substantially flat veneer press, the thermal expansion in the length and width directions can be determined. Therefore, when manufacturing the pressing device (for example at cold, i.e. when the pressing device is not running in the simultaneous embossing process), the length and the width of the pressing device can be scaled to determine the new length and the new width thereof at the time of manufacture.

[0038] Preferably, the one or more second scaling values are in the range of 0.9 to 1.1, preferably in the range of 0.95 to 1.05, more preferably in the range of 0.98 to 1.02, more preferably in the range of 0.99 to 1.01, more preferably in the range of 0.994 to 1.006, more preferably in the range of 0.996 to 1.004, most preferably in the range of 0.998 to 1.002.

[0039] The one or more second scaling values are chosen such that any dimensional changes are compensated in an unprecedented way. The one or more second scaling values can also be larger or smaller depending on the specific situation.

[0040] Preferably, the decorative paper is provided by printing a decorative pattern on the paper, preferably by digital printing.

[0041] This has the advantage that the printing process can be more easily automated. Furthermore, any type of decorative pattern can be more easily used. Digital printing can be implemented by various known means. For example, RGB / CMYK or separate data can be used.

[0042] Preferably, the decorative pattern is provided by an image taken by a camera or scanner, preferably by an image from a natural landscape.

[0043] For example, the image can be captured by a camera or can be taken using a scanner, such as an industrial scanner. The image can be optimized using software, including but not limited to Adobe Photoshop. It is advantageous if the resolution of the image is for example more than 100 dpi, 200 dpi, 300 dpi, or even more than 400 dpi.

[0044] Preferably, the decorative pattern mimics a natural pattern, preferably a wood grain surface, stone, tile or the like.

[0045] This has the advantage that a more natural look can be provided. The decorative pattern can mimic any surface that a consumer desires.

[0046] Preferably, the decorative pattern applied on the carrier board has a substantially unique pattern in the range of at least 2 meters, preferably at least 3 meters, more preferably at least 4 meters, more preferably at least 4.5 meters, more preferably at least 5.0 meters, more preferably at least 5.5 meters, most preferably at least 6.0 meters in the length direction of the carrier board.

[0047] This has the advantage that a considerable unique pattern can be achieved on the embossed decorative paper that is finally formed. In the prior art, when using gravure printing or similar methods, the provision of a larger unique pattern is limited by the diameter of the gravure cylinder.

[0048] "Unique pattern" can be understood as a pattern that is not repeated.

[0049] Preferably, the carrier board is medium density fiberboard (MDF), high density fiberboard (HDF), particle board, compact laminate or high pressure laminate (HPL).

[0050] The material is readily available and has proven to be beneficial. The carrier board (also referred to as "board" hereinafter for brevity) can be a board made of a wooden material. In another example, the board can also be made of a plastic material, such as stone plastic composite (SPC), luxury vinyl tile (LVT), rigid polymer core or foamed polymer core, and hybrid constructions widely used in the flooring industry.

[0051] Preferably, the simultaneous embossing process is carried out at a temperature of at least 100 °C, preferably at least 140 °C, more preferably at least 180 °C, most preferably at least 200 °C; and / or at a temperature of at most 300 °C, preferably at most 260 °C, more preferably at most 240 °C, most preferably at most 220 °C.

[0052] For the simultaneous embossing process to function properly, the temperature should neither be too high nor too low. Therefore, an optimal balance should be achieved as described above.

[0053] Preferably, the simultaneous embossing process is carried out at a pressure of 20 to 160 bar, preferably 30 to 140 bar, further preferably 40 to 120 bar, further preferably 50 to 100 bar, most preferably 60 to 90 bar.

[0054] For the simultaneous embossing process to function properly, the pressure should neither be too high nor too low. Therefore, an optimal balance should be achieved as described above.

[0055] Preferably, the simultaneous embossing process is a continuous pressing process.

[0056] Preferably, the pressing device is a veneer press, a press belt, a double belt press or a gravure cylinder, preferably a substantially flat veneer press, also used to form an embossing structure on the main surface of the carrier board substantially matching the decorative pattern of the decorative paper.

[0057] While it is advantageous to employ any pressing device according to the present disclosure, it is particularly beneficial to use a veneer press, such as a substantially flat veneer press. The advantage of this approach is that a larger unique pattern can be achieved on the finally formed embossed decorative paper. In particular, the decorative pattern is no longer limited by the diameter of the gravure cylinder (as in gravure printing). Thus, the method and board described herein can achieve a unique pattern that is, for example, at least four times larger than a conventional board.

[0058] Generally, such cylinders used for embossing have limitations: if a larger unique pattern is to be achieved, their diameter has to be increased. While an increased diameter leads to rising costs. Therefore, a veneer press facilitates a more cost-effective method and board.

[0059] Furthermore, it is no longer necessary for the decorative pattern to present the appearance of a continuous loop, since the requirement for continuity, for example with a gravure cylinder, is no longer necessary. As a result, a higher level of realism can be achieved compared to, for example, a gravure cylinder conventionally used.

[0060] Preferably, the decorative paper is treated with a thermosetting resin, for example a phenol resin, a melamine resin or a formaldehyde resin, preferably a melamine resin.

[0061] Such resins are readily available. Furthermore, the quality of the decorative paper can be improved.

[0062] The method can also comprise applying a primer layer, a varnish layer and / or a wear layer on the carrier board. The wear layer can be based on cast polypropylene. The varnish layer can provide sufficient elasticity to compensate for deformation of the board.

[0063] Panel Another aspect relates to a board manufactured by the method described herein.

[0064] As described elsewhere herein, it will be understood that substantially the same advantages and features mentioned in relation to the method of manufacturing a board equally apply to the board. Furthermore, these features can be applied in combination, or interchangeably between embodiments of the board and the manufacturing method.

[0065] The manufactured board has a better overall appearance. In particular, the decorative effect is improved, since the decorative pattern can be provided uniquely on the carrier board in a relatively large area. Furthermore, the synchronicity of the decorative pattern on the carrier board with the embossed structure is enhanced, which can be visually embodied in the manufactured board.

[0066] In one example, the embossed structure on the carrier board is visible from the top thereof. This is beneficial, since it contributes to presenting a more natural appearance when viewed from the top. The board also exhibits a better quality, and tactile advantages can be achieved. As a result, the structural performance of the board is enhanced.

[0067] Preferably, the board is designed as a wallboard, a ceiling, furniture or a floorboard, which comprises a coupling element for coupling with another similar board.

[0068] Preferably, the width of the board is at least 8 cm, preferably at least 20 cm, more preferably at least 30 cm, more preferably at least 40 cm, most preferably at least 50 cm; and / or at most 260 cm, preferably at most 210 cm, more preferably at most 200 cm, more preferably at most 180 cm, more preferably at most 140 cm, most preferably at most 100 cm.

[0069] The width should not be too large or too small. As a result, an optimal balance should be achieved as described above.

[0070] These widths have proven to provide a better optical and haptic quality, while maintaining a high level of robustness and mechanical integrity.

[0071] As generally applicable in the present disclosure, when referring to a geometric property (e.g. length, width, etc.) of a board and / or a board component, any lower limit and / or upper limit of said geometric property can be combined to form a range.

[0072] Preferably, the length of the board is at least 40 cm, preferably at least 50 cm, more preferably at least 60 cm, more preferably at least 80 cm, most preferably at least 100 cm; and / or at most 580 cm, preferably at most 560 cm, more preferably at most 500 cm, more preferably at most 450 cm, most preferably at most 400 cm.

[0073] The length should not be too large or too small. Therefore, an optimal balance should be achieved as described above. The length can be chosen independently of any decorative pattern, as the decorative pattern can be provided uniquely over a large range in the length direction of the board.

[0074] Preferably, the thickness of the board is at least 4 mm, preferably at least 6 mm, more preferably at least 8 mm, more preferably at least 10 mm, more preferably at least 12 mm, more preferably at least 14 mm, more preferably at least 16 mm, more preferably at least 18 mm, most preferably at least 20 mm; and / or at most 50 mm, preferably at most 40 mm, more preferably at most 35 mm, more preferably at most 30 mm, most preferably at most 25 mm.

[0075] Preferably, the thickness of the printed paper applied on the carrier board is at least 5 pm, preferably at least 10 pm, more preferably at least 20 pm, more preferably at least 30 pm, more preferably at least 40 pm, most preferably at least 50 pm; and / or at most 200 pm, preferably at most 150 pm, more preferably at most 100 pm, more preferably at most 90 pm, most preferably at most 80 pm.

[0076] The thickness of the printed paper should not be too small or too large. A larger thickness helps to improve the printing and / or the simultaneous embossing process, can provide a stronger robustness or stiffness. A smaller thickness, on the other hand, helps to save material. Therefore, an optimal balance should be achieved as described above.

[0077] Another aspect relates to a system for manufacturing a board, in particular a wallboard, a ceiling, furniture or a floorboard, the system comprising: a carrier board; a decorative paper with a decorative pattern; and a pressing device with an embossing structure; wherein the pressing device is configured to perform a simultaneous embossing process with the carrier board and the decorative paper; wherein, when manufacturing the paper with the decorative pattern and / or the embossing device with the embossed structure, a dimensional change of the decorative paper and / or the embossing device during the manufacturing process of the board material is taken into account.

[0078] Another aspect relates to a method for manufacturing an embossing device for use in a simultaneous embossing process, the method according to any of the aspects and / or embodiments described herein, comprising the steps of: providing an embossing device with an embossed structure; wherein, when manufacturing the embossing device with the embossed structure, a dimensional change of the decorative paper and / or the embossing device during the manufacturing process of the board material is taken into account.

[0079] As described elsewhere herein, it is to be understood that substantially the same advantages and features mentioned with respect to the method of manufacturing a board and the board apply equally to the system of manufacturing a board and the method of manufacturing an embossing device. Furthermore, these features can be applied and / or interchanged between embodiments of the system, the method of manufacturing an embossing device, the board and the method of manufacturing a board. BRIEF DESCRIPTION OF DRAWINGS

[0080] In the following, preferred embodiments are described by way of example only. Reference is made to the following drawings: Figure 1 A schematic diagram of an exemplary method according to the present disclosure is shown.

[0081] Figure 2 A side view of a board according to an embodiment of the present disclosure is shown.

[0082] Figure 3 An exemplary data of dimensional changes of an embossing device and a decorative paper according to the present disclosure is shown. Figure 2 A top view of the shown embodiment.

[0083] Figure 4 An exemplary data of dimensional changes of an embossing device and a decorative paper according to the present disclosure is shown.

[0084] Figure 5 A status of an exemplary embossing device and embossing plate according to an embodiment of the present disclosure is shown from top, in hot and cold state. DETAILED DESCRIPTION

[0085] Subsequently, the presently preferred embodiments will be outlined with reference to the above-mentioned figures. It should be noted that other embodiments are of course possible as well, the following description is provided by way of example only and does not constitute a limitation. Furthermore, the present disclosure can also be applied to other embodiments not explicitly disclosed below. Moreover, as described below, the embodiments are compatible with each other, individual features of one embodiment can also be applied to another embodiment.

[0086] In the present specification and the drawings, like reference numerals denote like elements. The drawings can not be to scale, and the relative dimensions, proportions and depictions of the elements in the drawings can be exaggerated for clarity, illustration and convenience.

[0087] Figure 1 A schematic representation of an exemplary method 100 for manufacturing a board according to the present disclosure is shown. In particular, a method 100 for manufacturing a board 1, in particular a wall, ceiling, furniture or floor board, by a simultaneous embossing process is shown, the method 100 comprising the steps of providing 110 a carrier board; providing 120 a decorative paper having a decorative pattern; and providing 130 a pressing device having an embossing structure; wherein the dimensional changes of the decorative paper and / or the pressing device during the manufacturing process of the board are taken into account when providing the decorative paper having the decorative pattern and / or the pressing device having the embossing structure.

[0088] The simultaneous embossing process comprises embossing the board, thereby forming an embossing structure on the board to which the decorative paper has been applied. The pressing device can be a veneer press.

[0089] As described herein, the method is also advantageous for providing a relatively long unique pattern repeat. To this end, it can be beneficial to modify the alignment marks of the camera used in the impregnation process. For example, instead of rectangular marks, triangular shaped marks can be used in the center of the technical mark area. Furthermore, it can be beneficial to add an indication such as “front” and / or “back” in the technical mark area. Thereby, wrong cutting and / or wrong pressing of the impregnation paper during production can be avoided.

[0090] Figure 2 A side view of a board 1 according to an embodiment of the present disclosure is shown. The board 1 can be a wall, ceiling, furniture or floor board. The board 1 can be a laminate board. The board 1 can be a laminate board. The board 1 comprises a carrier board 10, for example a medium density fiberboard (MDF) carrier board, a high density fiberboard (HDF) carrier board or a particle board.

[0091] The board 1 includes decorative paper 20 with a decorative pattern 21. The decorative pattern 21 can be provided as an image, which is printed onto the paper to form the decorative paper 20. For example, the natural object to be reproduced (e.g., a slate) can be photographed or digitized using an industrial scanner. The digital image can be processed using a computer to form a continuous loop. Furthermore, defects can be removed, the pattern optimized, and color settings adjusted to achieve the desired effect. Depending on the format of the natural object, the pattern repeat length is typically at least 4.1 meters and can be up to 5.6 meters. The image can then be converted from its existing format and prepared for paper printing according to the number of colors used by the industrial digital printer. For example, raster image processor (RIP) software can be used. The prepared image can be uploaded to the digital printer. The image can be printed continuously on the paper in a roll-to-roll manner. This allows for multiple pattern repeats to be performed continuously, with these pattern repeats seamlessly connected. Thus, an impression of an infinite number of patterns can be provided.

[0092] The decorative paper 20 can be impregnated with resin, such as thermosetting resins like phenolic resin, melamine resin, or formaldehyde resin, preferably melamine resin. The decorative paper 20 and the board 10 have an embossed structure 22, which is synchronized with the decorative pattern 21 by the synchronous embossing process of this disclosure.

[0093] The board 10 has a top surface 15 opposite to the back surface 17. Decorative paper 20 is applied to the top surface. Thus, the decorative appearance of the decorative paper 20 can be identified, which is desirable. The back surface 17 typically faces the floor, wall panel, ceiling, etc., depending on the application area of ​​the board 1.

[0094] The sheet material 1 also includes a connecting structure 30 on at least one side 16 of the sheet 10. The side 16 is substantially parallel to the thickness direction of the sheet 10. The connecting structure 30 allows the side 16 to engage with the side of another sheet. This can be achieved by contouring the sheet. Contouring may also include providing the connecting structure 30 on both sides.

[0095] Figure 3 It shows Figure 2 The illustrated embodiment is shown as a top view. Exemplarily, the decorative pattern 21 of the decorative paper 20 is substantially synchronized with the embossed structure 22 formed on the plate 10 and the decorative paper 20 by a pressing device. The width wp and longitudinal extension length L of the plate 10 are also shown in this figure.

[0096] Figure 4Exemplary data of dimensional changes of a pressing device and a decor paper according to the present disclosure is shown. The data in this graph can not be drawn to scale. In this example, the width of the cold lower platen (this can be the platen of a veneer press) is 2072.57 mm. The width of the hot lower platen is 2076 mm. In addition, the graph also shows the expansion rate of the decor paper (in %). It can be seen that the expansion rate varies with position (e.g. width direction). For example, at the outer regions, the expansion rate is higher than the central region along the width direction. Based on these dimensional changes, the image data width indicated in the graph is 2051.38 mm. The difference can be derived as (2076 mm - 2051.38 mm) / 2076 mm ~ 1.2%.

[0097] Figure 5 Exemplary pressing device 50 according to embodiments of the present disclosure is shown along with the state of the embossing plate at hot and cold states. It is shown that at hot state (pressing device 50 at the top of the graph), the length is 5260 mm and the width is 2076 mm. The length of the impregnated film is 4060 mm. It is shown that at cold state (pressing device 50 at the bottom of the graph), the length is 5251.32 mm and the width is 2072.57 mm. Based on these data, a coefficient of 5251.32 mm / 5260 mm = 0.99835 can be derived for calculating the length of the cold pressing device 50 from the length of the given hot pressing device 50.

[0098] Generally, the methods described herein can employ digital printing, which in the prior art is generally only considered as a technique to provide test samples. At later stages of the product development process in the prior art, gravure printing techniques are generally employed without taking into account any dimensional changes. As a result, the decor pattern is generally limited to a limited size for this reason. In view of the present disclosure, the inventors have found a way to be able to take into account dimensional changes when carrying out a digital printing and simultaneous embossing process.

[0099] It will be appreciated that the above examples can be combined with other aspects described herein, and that details of these examples can also be omitted, as will be appreciated by the skilled person. The scope of protection is defined by the claims, which are not limited by the embodiments disclosed in the above description and in the accompanying drawings.

[0100] Numerous modifications and variations of the described examples and implementations are possible in light of the above teachings. The disclosed examples and implementations are intended to be illustrative only. Other embodiments can include some or all of the features disclosed herein. Accordingly, the scope of protection is not intended to be limited to the described examples and implementations.

[0101] List of reference signs 1 board 10 carrier plate 15 top surface 16 side 17 back 20 decor paper 21 decor pattern 22 embossed structure 30 connecting structure / coupling element 50 pressing device L longitudinal extension of the board wp width of the board 100 method for manufacturing a board 110 providing a carrier board 120 providing a decor paper 130 providing a pressing device 200 method for manufacturing a pressing device 1000 system for manufacturing a board

Claims

1. A method (100) for manufacturing a board (1), in particular a wall, ceiling, furniture or floor board, by a synchronized embossing process, the method (100) comprising the steps of: providing (110) a carrier board (10); providing (120) a decorative paper (20) having a decorative pattern (21); and providing (130) a press device (50) having an embossing structure; wherein, when manufacturing the decorative paper (20) having the decorative pattern (21) and / or the press device (50) having the embossing structure, dimensional changes of the decorative paper (20) and / or the press device (50) during the manufacturing of the board (1) are taken into account.

2. The method (100) according to the preceding claim, wherein the decorative paper (20) having the decorative pattern (21) is manufactured by using a computer, scaling the dimensions of the decorative pattern (21) with one or more first scaling values.

3. The method (100) according to the preceding claim, wherein the method comprises impregnating the decorative paper, wherein the one or more first scaling values vary based at least partly on the dimensions of the decorative paper (20) during impregnation of the decorative paper (20).

4. The method (100) according to claim 2 or 3, wherein the one or more first scaling values vary locally with respect to the paper (20).

5. The method (100) according to any one of claims 2 to 4, wherein the one or more first scaling values are selected based on a predetermined functional relationship, preferably an expansion curve based on properties of the paper (20) and / or impregnation conditions.

6. The method (100) according to any one of claims 2 to 5, wherein the one or more first scaling values are in the range of 0.9 to 1.1, preferably in the range of 0.95 to 1.05, more preferably in the range of 0.98 to 1.02, further preferably in the range of 0.99 to 1.01, further preferably in the range of 0.994 to 1.006, further preferably in the range of 0.996 to 1.004, most preferably in the range of 0.998 to 1.

002.

7. The method (100) according to any one of the preceding claims, wherein the dimensions of the press device (50) are selected based on one or more second scaling values, the one or more second scaling values being based at least partly on thermal expansion of the press device (50) during the synchronized embossing process.

8. The method (100) according to the preceding claim, wherein the one or more second scaling values comprise a length scaling value for a length of the press device (50) and a width scaling value for a width of the press device (50).

9. The method (100) according to any of claims 7 or 8, wherein the one or more second scaling values are in the range of 0.9 to 1.1, preferably in the range of 0.95 to 1.05, more preferably in the range of 0.98 to 1.02, further preferably in the range of 0.99 to 1.01, further preferably in the range of 0.994 to 1.006, further preferably in the range of 0.996 to 1.004, most preferably in the range of 0.998 to 1.

002.

10. The method (100) according to any of the preceding claims, wherein the decorative paper (20) is provided by printing the decorative pattern (21) on the paper (20), preferably by digital printing.

11. The method (100) according to any of the preceding claims, wherein the decorative pattern (21) is provided by an image taken by a camera or scanner, preferably by an image from a natural landscape.

12. The method according to any of the preceding claims, wherein the decorative pattern (21) mimics a natural pattern, preferably a wood grain surface, stone, tile or similar.

13. The method (100) according to any of the preceding claims, wherein the decorative pattern (21) provided on the board (10) has a substantially unique pattern in the range of at least 2 meters, preferably at least 3 meters, more preferably at least 4 meters, further preferably at least 4.5 meters, further preferably at least 5.0 meters, further preferably at least 5.5 meters, most preferably at least 6.0 meters of board length.

14. The method (100) according to any of the preceding claims, wherein the carrier board (10) is medium density fiberboard (MDF), high density fiberboard (HDF), particle board, compact laminate or high pressure laminate.

15. The method (100) according to any of the preceding claims, wherein the simultaneous embossing process is performed at a temperature of at least 100 °C, preferably at least 140 °C, more preferably at least 180 °C, most preferably at least 200 °C; and / or at a temperature of at most 300 °C, preferably at most 260 °C, more preferably at most 240 °C, most preferably at most 220 °C.

16. The method (100) according to any of the preceding claims, wherein the simultaneous embossing process is performed at a pressure of 20 to 160 bar, preferably 30 to 140 bar, further preferably 40 to 120 bar, further preferably 50 to 100 bar, most preferably 60 to 90 bar.

17. The method (100) according to any of the preceding claims, wherein the simultaneous embossing process is a continuous pressing process.

18. The method (100) according to any of the preceding claims, wherein the pressing device (50) is a veneer press, a press belt, a double belt press, a gravure cylinder, preferably a substantially flat veneer press, for providing an embossed structure (22) on the main surface (15) of the board, the embossed structure (22) substantially matching the decorative pattern (21) of the decorative paper (20). ​ 19. The method (100) according to any of the preceding claims, wherein the decor paper (20) is provided with a thermosetting resin, such as a phenol resin, a melamine resin or a formaldehyde resin, preferably a melamine resin.

20. A panel (1) manufactured by the method (100) according to any of the preceding claims.

21. The panel (1) according to the preceding claim, designed as a wall panel, a ceiling panel, furniture or a floor panel, comprising a coupling element (30) configured to couple with another similar panel (1).

22. The panel (1) according to any of claims 20 or 21, wherein the width of the panel (1) is at least 8 cm, preferably at least 20 cm, more preferably at least 30 cm, further preferably at least 40 cm, most preferably at least 50 cm, and / or at most 260 cm, preferably at most 210 cm, more preferably at most 200 cm, further preferably at most 180 cm, further preferably at most 140 cm, most preferably at most 100 cm.

23. The panel (1) according to any of claims 20 to 22, wherein the length of the panel (1) is at least 40 cm, preferably at least 50 cm, more preferably at least 60 cm, further preferably at least 80 cm, most preferably at least 100 cm, and / or at most 580 cm, preferably at most 560 cm, more preferably at most 500 cm, further preferably at most 450 cm, most preferably at most 400 cm.

24. The panel (1) according to any of claims 20 to 23, wherein the thickness of the panel (1) is at least 4 mm, preferably at least 6 mm, more preferably at least 8 mm, further preferably at least 10 mm, further preferably at least 12 mm, further preferably at least 14 mm, further preferably at least 16 mm, further preferably at least 18 mm, most preferably at least 20 mm, and / or at most 50 mm, preferably at most 40 mm, more preferably at most 35 mm, further preferably at most 30 mm, most preferably at most 25 mm.

25. The panel (1) according to any of claims 20 to 24, wherein the thickness of the printed paper applied on the panel is at least 5 pm, preferably at least 10 pm, more preferably at least 20 pm, further preferably at least 30 pm, further preferably at least 40 pm, most preferably at least 50 pm, and / or at most 200 pm, preferably at most 150 pm, more preferably at most 100 pm, further preferably at most 90 pm, most preferably at most 80 pm.

26. A system (1000) for manufacturing a panel (1), in particular a wall panel, a ceiling panel, furniture or a floor panel, the system (1000) comprising: a carrier panel (10); a decor paper (20) having a decor pattern (21); and a pressing device (50) having an embossed structure; wherein the pressing device (50) is configured to perform a synchronized embossing process with the panel (10) and the decor paper (20). wherein, in manufacturing the paper (20) having the decorative pattern (21) and / or the pressing device (50) having the embossed structure, dimensional variations of the decorative paper (20) and / or the pressing device (50) during the manufacturing process of the panel (1) are taken into account.

27. A method (200) for manufacturing a pressing device (50) used in a simultaneous embossing process according to any of the preceding method claims, the method comprising the steps of: providing a pressing device (50) having an embossed structure; wherein, in manufacturing the pressing device (50) having the embossed structure, dimensional variations of the decorative paper (20) and / or the pressing device (50) during the manufacturing process of the panel (1) are taken into account.

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