Method for producing laminated substrate having embossed structure

Abstract

The present disclosure relates to a method of producing a laminated substrate (20) having an embossed structure, comprising: providing a polymeric base film (1) printed by at least one first gravure cylinder (2) forming a first pattern (11) and a second gravure cylinder (4) forming a second pattern (12), where the circumference (C2) of the second gravure cylinder (4) is greater than the circumference (C1) of the first gravure cylinder (2); the polymer-based film (1) is applied to a substrate (10; 10 ') comprising a polymer-based material. The present invention relates to a method for producing a polymer-based film (1) on a substrate (10, 10 '), pressing the polymer-based film (1) onto the substrate (10, 10') to form a laminated substrate (20), and embossing the laminated substrate (20) by means of an embossing device (30) such that the laminated substrate (20) obtains an embossed structure wherein a circumference (C3, C4) of the embossing device (30) corresponds to a circumference (C1) of the first gravure cylinder (2) or a circumference (C2) of the second gravure cylinder (4).

Description

Technical Field

[0001] Embodiments of the present disclosure relate to a method of producing a laminate substrate having an embossed structure. Background Art

[0002] Panels such as architectural panels may have prints for decorative purposes. The print may be a wood grain pattern that simulates wood. In other examples, the print may be a stone pattern that simulates stone, or a fantasy pattern. To increase the realism of the panel, the panel may have an embossed structure, including embossed portions and protrusions. The embossed structure may be aligned with the print so that the embossed structure matches elements of the print. Elements of the print may be wood grain, knots, medullary rays, and other elements that depict the structure of the wood.

[0003] Prints can be printed using various methods. One common method is rotogravure printing, where the pattern is printed by several gravure cylinders. Digital printing allows for more variations in prints and is therefore more flexible than engraving gravure cylinders.

[0004] Vinyl tiles have become increasingly successful in the flooring sector in recent years. One type of tile is SPC (Stone Plastic Composite), where the core is formed by extruding a core material in a continuous process. The pattern is provided by a separate printed film, most commonly printed by rotogravure. The printed film and a protective layer arranged over the printed film are pressed onto the core by one or more pressing rollers. An embossing roller can press the embossed structure into the panel.

[0005] Due to the cost of engraved gravure cylinders and embossing rollers, the number of unique designs is limited. Therefore, after the substrate is divided into individual panels, a certain repetition of the pattern occurs after a certain number of panels. Such repetition is undesirable when installing the floor. Therefore, it is desirable to increase the number of variations and reduce the number of identical panels to improve the realistic look of the floor. Summary of the invention

[0006] It is an object of at least some embodiments of the present disclosure to provide improvements over the above-mentioned techniques and known techniques.

[0007] According to a first aspect of the present disclosure, a method for producing a laminated substrate having an embossed structure is provided. The method comprises: providing a polymer-based film (i.e., a polymer-based film) printed by at least one first gravure cylinder forming a first pattern and a second gravure cylinder forming a second pattern, wherein the circumference of the second gravure cylinder is greater than the circumference of the first gravure cylinder; applying the polymer-based film to a substrate comprising a polymer-based material (i.e., a polymer-based material); pressing the polymer-based film onto the substrate to form a laminated substrate; and embossing the laminated substrate by an embossing device so that the laminated substrate obtains an embossed structure, wherein the circumference of the embossing device corresponds to the circumference of the first gravure cylinder or to the circumference of the second gravure cylinder.

[0008] The terms "first" and "second" are not limited to any sequential arrangement but are merely used to distinguish between a plurality of gravure cylinders.

[0009] The first pattern may be different from the second pattern. The first pattern may be different from the second pattern.

[0010] As an alternative, one of the first or second gravure cylinder may be replaced by a digital printing method, such as inkjet printing.

[0011] The embossing device may be an embossing roller or an embossing belt.

[0012] The embossed structure of the embossing device may correspond completely or at least partially to the first pattern or the second pattern. Thus, the embossed structure may be completely aligned or at least partially aligned with the first pattern or the second pattern. Typically, the pattern of the gravure cylinder includes a large number of design elements. The embossed structure corresponding to the gravure cylinder pattern usually includes a portion of the design elements. If the pattern of the gravure cylinder is very complex or crowded, a complete embossing aligned with such a pattern may have an unfavorable appearance. Therefore, the embossed structure may be aligned with all or at least a portion of the first pattern or the second pattern.

[0013] Pressing and embossing may be performed simultaneously. Pressing and embossing may be performed by a common device, such as an embossing roller or an embossing belt configured for both pressing and embossing.

[0014] The substrate may have a certain length and width. The polymer-based film may have a certain length and width. The length direction of the polymer-based film may be substantially parallel to the length direction of the substrate.

[0015] The circumference of the embossing device may correspond to the circumference of the first intaglio cylinder, such that the first pattern formed by the first intaglio cylinder is at least partially aligned with the embossed structure.

[0016] The second pattern formed by the second gravure cylinder may be out of alignment, or at least not completely aligned, with the embossed structure.

[0017] The second pattern formed by the second gravure cylinder is typically not aligned with the embossed structure, or is aligned with only a portion of the embossed structure.

[0018] The first pattern may include a first set of design elements and the second pattern may include a second set of design elements, wherein the embossed structure may be aligned with the first set of design elements.

[0019] The circumference of the embossing device may correspond to the circumference of the second intaglio cylinder, so that the second pattern formed by the second intaglio cylinder is aligned with the embossed structure.

[0020] The circumference of the embossing device may correspond to the circumference of the second intaglio cylinder, so that the second pattern formed by the second intaglio cylinder is aligned with the embossed structure or a portion of the embossed structure.

[0021] The first pattern formed by the first gravure cylinder may be out of alignment, or at least not completely aligned, with the embossed structure.

[0022] The first pattern may include a first set of design elements and the second pattern may include a second set of design elements, wherein the embossed structure may be aligned with the second set of design elements.

[0023] The first pattern and / or the second pattern may be a wood grain pattern.

[0024] The first pattern may add at least one knot, crack and / or medullary ray to the second pattern, or the second pattern may add at least one knot, crack and / or medullary ray to the first pattern.

[0025] The method may further comprise dividing the laminate substrate into a plurality of panels, wherein the length of the panels may substantially correspond to the circumference of the embossing device.

[0026] The length of the panels may substantially correspond to the circumference of the first intaglio cylinder or to the circumference of the second intaglio cylinder.

[0027] If the first or second gravure cylinder comprises a pattern repeat containing more than one pattern, the length of the panel may correspond to a portion of the circumference of the first gravure cylinder or a portion of the circumference of the second gravure cylinder. The length of the panel may correspond to the length of a single pattern in the pattern repeat of the first pattern or the second pattern. Each pattern in the pattern repeat may have the same length.

[0028] The panels may be planks or tiles.

[0029] Each panel may be of the same length.

[0030] The substrate may be formed by a continuous process.

[0031] The polymer-based film may be applied continuously to the substrate.

[0032] The polymer-based film may be applied in-line with the production process of the substrate.

[0033] Forming the substrate and applying the polymer-based film may be a continuous process.

[0034] The substrate may be formed by extrusion.

[0035] The barrel temperature of the extruder can be 145-225°C.

[0036] The polymer-based film may be applied to the substrate prior to cooling the substrate.

[0037] The polymer of the polymer base film may be a thermoplastic polymer.

[0038] The polymer of the polymer-based film may be a thermosetting polymer.

[0039] The polymer-based film may be paper-free, for example, non-paper-based.

[0040] The polymer-based film may be made of a polymer material such as a thermoplastic or a thermosetting material.

[0041] The polymer base film may be a PVC film.

[0042] The polymer-based material of the substrate may be a thermoplastic material or a thermosetting material.

[0043] The substrate may further comprise a filler. The filler may be an organic and / or inorganic filler. The filler may be one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, sawdust, crushed rice husk, cork and bamboo shavings.

[0044] Pressing may include applying heat and pressure.

[0045] The method may further include applying a protective layer to the polymer-based film prior to embossing.

[0046] The protective layer may be a polymer-based film, such as a thermoplastic film or a thermosetting film.

[0047] According to a second aspect, there is provided a method for producing a laminate substrate having an embossed structure. The method comprises:

[0048] providing a polymer base film having a first pattern printed by at least one first gravure cylinder and a second pattern printed by digital printing,

[0049] applying a polymer-based film to a substrate comprising a polymer-based material,

[0050] pressing the polymer-based film onto a substrate to form a laminated substrate, and

[0051] The laminated substrate is embossed by an embossing device so that the laminated substrate acquires an embossed structure, wherein the circumference of the embossing device corresponds to the circumference of the first gravure cylinder or corresponds to the pattern repeat length of the second pattern.

[0052] The digital printing method may be inkjet printing.

[0053] The first pattern and the second pattern may be different. The first pattern and the second pattern may be different.

[0054] The pattern repeat length is measured in the length direction of the polymer base film.

[0055] If the second pattern includes two or more separate patterns, the patterns are continuous with each other in the length direction of the polymer base film.Each pattern in the pattern repeat is different from other patterns in the pattern repeat.

[0056] The pattern repeat length may be measured from the start point of the first pattern in the pattern repeat to the end point of the last pattern in the pattern repeat and is measured in the length direction of the polymer base film.

[0057] If the second pattern includes one pattern, the length of the pattern in the length direction of the polymer base film corresponds to the length of the pattern repeating portion in the length direction of the polymer base film.

[0058] The length of the pattern repeat of the second pattern may exceed the circumference of the first gravure cylinder.

[0059] The substrate may have a certain length and width. The polymer-based film may have a certain length and width. The length direction of the polymer-based film may be substantially parallel to the length direction of the substrate.

[0060] The embossing device may be an embossing roller or an embossing belt.

[0061] The embossed structure of the embossing device may correspond completely or at least partially to the first pattern or the second pattern.Thereby, the embossed structure may be completely or at least partially aligned with the first pattern or the second pattern.

[0062] Pressing and embossing may be performed simultaneously. Pressing and embossing may be performed by a common device, such as an embossing roller or an embossing belt configured for both pressing and embossing.

[0063] The circumference of the embossing device may correspond to the circumference of the first intaglio cylinder, such that the first pattern formed by the first intaglio cylinder is at least partially aligned with the embossed structure.

[0064] The second pattern formed by digital printing may not be aligned, or at least not completely aligned, with the embossed structure.

[0065] The first pattern may include a first set of design elements and the second pattern may include a second set of design elements, wherein the embossed structure may be aligned with the first set of design elements.

[0066] The perimeter of the embossing device may correspond to the length of the pattern repeat portion of the second pattern, so that the second pattern formed by digital printing is aligned with the embossed structure. The perimeter of the embossing device may correspond to the length of the pattern repeat portion of the second pattern, so that at least a portion of the second pattern formed by digital printing is aligned with the embossed structure.

[0067] The first pattern formed by the first gravure cylinder may be out of alignment, or at least not completely aligned, with the embossed structure.

[0068] The first pattern may include a first set of design elements and the second pattern may include a second set of design elements, wherein the embossed structure may be aligned with the second set of design elements.

[0069] The first pattern and / or the second pattern may be a wood grain pattern.

[0070] The first pattern may add at least one knot, crack and / or at least one medullary ray to the second pattern, or the second pattern may add at least one knot, crack and / or at least one medullary ray to the first pattern.

[0071] The method may further comprise dividing the laminate substrate into a plurality of panels, wherein the length of the panels may substantially correspond to the circumference of the embossing device.

[0072] The length of the panel may substantially correspond to the length of the first pattern or the pattern repeat length of the second pattern.

[0073] The length of the panel may correspond to a portion of the circumference of the first gravure cylinder or a portion of the pattern repeat length of the second pattern. The length of the panel may correspond to the length of a single pattern of the pattern repeat of the first pattern or the second pattern. Each pattern in the pattern repeat may have the same length.

[0074] The panels may be planks or tiles.

[0075] The substrate may be formed by a continuous process.

[0076] The polymer-based film may be applied continuously to the substrate.

[0077] The polymer-based film can be applied in-line during the production process of the substrate.

[0078] Forming the substrate and applying the polymer-based film can be a continuous process.

[0079] The substrate may be formed by extrusion.

[0080] The barrel temperature of the extruder can be 145-225°C.

[0081] The polymer-based film may be applied to the substrate prior to cooling the substrate.

[0082] The polymer of the polymer base film may be a thermoplastic polymer.

[0083] The polymer of the polymer-based film may be a thermosetting polymer.

[0084] The polymer-based film may be paper-free, for example, non-paper-based.

[0085] The polymer-based film may be made of a polymer material, such as a thermoplastic or a thermoset material.

[0086] The polymer base film may be a PVC film.

[0087] The polymer-based material of the substrate may be a thermoplastic material or a thermosetting material.

[0088] The substrate may further comprise a filler. The filler may be an organic and / or inorganic filler. The filler may be one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, sawdust, crushed rice husk, cork and bamboo shavings.

[0089] Pressing may include applying heat and pressure.

[0090] The method may further include applying a protective layer to the polymer-based film prior to embossing.

[0091] The protective layer may be a polymer-based film, such as a thermoplastic film or a thermosetting film. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] The present disclosure will be described in more detail, by way of example, with reference to the accompanying schematic drawings, which show embodiments of the present disclosure.

[0093] Figure 1 The rotogravure printing process of a polymer-based film is schematically shown.

[0094] Figure 2 A combined printing process for a polymer-based film, including digital printing and rotogravure printing, is schematically shown.

[0095] Figure 3A A portion of a printed polymer-based film is shown, comprising a first pattern.

[0096] Figure 3B A portion of a printed polymer-based film is shown, comprising a second pattern.

[0097] Figure 3CA portion of a printed polymer-based film is shown, comprising a first pattern and a second pattern.

[0098] Figure 4 A process for forming a laminate substrate according to a first example is schematically illustrated.

[0099] Figure 5 A process for forming a laminate substrate according to a second example is schematically illustrated.

[0100] Figure 6 A process for forming a laminate substrate according to a third example is schematically illustrated.

[0101] Figure 7 A top view of a laminate substrate according to a first example is shown.

[0102] Figure 8 A top view of a laminate substrate according to a second example is shown.

[0103] Fig. 9 A top view of a laminate substrate according to a third example is shown. DETAILED DESCRIPTION

[0104] Figure 1 Schematic diagram of a cross-section of the rotogravure printing process. In rotogravure printing, one or more gravure cylinders apply the ink to the substrate to be printed. Traditionally, one gravure cylinder applies one color. For CMYK, the rotogravure printing process involves four gravure cylinders. Figure 1 , a cross section of a gravure cylinder is schematically shown.

[0105] In rotary gravure printing, ink 6 is placed in an ink tray 7, and gravure cylinders 2, 4 are dipped into the ink tray 7 to transfer ink 6 from the ink tray 7 to the substrate to be printed. The gravure cylinders 2, 4 are engraved with a pattern. A doctor blade 5 removes excess ink 6 on the gravure cylinders 2, 4 so that the ink 6 exists only in the concave portions of the engraved pattern of the gravure cylinders. The substrate passes between the gravure cylinders 2, 4 and the impression roller 3. Thus, the ink 6 is transferred from the gravure cylinders 2, 4 to the surface of the substrate. This process is repeated for each color applied.

[0106] In the present disclosure, the substrate to be printed is a polymer base film 1. The polymer base film 1 may be a thermoplastic film. The polymer base film 1 may be a thermosetting film. In one example, the polymer base film 1 may not contain paper.

[0107] The polymer base film 1 may be made of a polymer material, which may be a thermoplastic or thermosetting material.

[0108] The polymer base film 1 can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0109] In one example, the polymer base film 1 is a PVC film; in another example, the polymer base film may be a thermosetting PU film.

[0110] The polymer base film 1 may have a thickness of 0.01 to 0.1 mm.

[0111] The polymer base film 1 may have a rectangular shape, for example, having a certain length and width. The length may exceed the width of the polymer base film 1.

[0112] The size of the polymer-based film 1 may substantially correspond to the size of a substrate to which the polymer-based film 1 will be applied in a subsequent step. The width of the polymer-based film 1 may be 1-1.5 m, for example 1 m or 1.3 m.

[0113] In one example, the polymer base film 1 is formed by referring to Figure 1 The printing was carried out by the rotogravure process described.

[0114] The polymer base film 1 is printed by a first gravure cylinder 2 , and one or more patterns are engraved on the first gravure cylinder 2 when viewed along the rotation direction of the first gravure cylinder 2 .

[0115] The first gravure cylinder 2 has a circumference C1. The first gravure cylinder 2 has a rotation axis which may be arranged parallel to the width direction of the polymer base film 1 to be printed. The first gravure cylinder 2 may have a length extension direction parallel to the width direction of the polymer base film 1 to be printed.

[0116] Typically, the circumference C1 of the first gravure cylinder 2 is less than the length of the polymer base film 1, so that the one or more patterns of the first gravure cylinder 2 are repeated on the polymer base film 1. The one or more patterns define a pattern repeating portion, which has a certain pattern repeating length. Each pattern of the pattern repeating portion is unique and is not the same as or equal to other patterns of the pattern repeating portion. The pattern repeating length substantially corresponds to the circumference C1 of the first gravure cylinder 2.

[0117] The polymer base film 1 is also printed by a second gravure cylinder 4, and one or more patterns are engraved on the second gravure cylinder 4 as viewed in the rotation direction of the second gravure cylinder 4. The circumference C2 of the second gravure cylinder 4 is different from the circumference of the first gravure cylinder 2. The circumference C2 of the second gravure cylinder 4 may exceed the circumference C1 of the first gravure cylinder 2.

[0118] The second gravure cylinder 4 may be located behind the first gravure cylinder 2 in the printing direction, or may be located in front of the first gravure cylinder 2 in the printing direction. The terms "first" and "second" are only used to distinguish one gravure cylinder from another.

[0119] The second gravure cylinder 4 has a rotation axis which may be arranged parallel to the width direction of the to-be-printed polymer base film 1. The second gravure cylinder 4 may have a length extension direction parallel to the width direction of the to-be-printed polymer base film 1.

[0120] Typically, the circumference C2 of the second gravure cylinder 4 is less than the length of the polymer base film 1, so that the one or more patterns of the second gravure cylinder 4 are repeated on the polymer base film 1. The one or more patterns define a pattern repeating portion, which has a certain pattern repeating length. Each pattern of the pattern repeating portion is unique and is not the same or identical to other patterns of the pattern repeating portion. The pattern repeating length substantially corresponds to the circumference C2 of the second gravure cylinder 4.

[0121] Since the circumference C1 of the first gravure cylinder 2 is not equal to the circumference C2 of the second gravure cylinder 4, the pattern repeat lengths of the gravure cylinders 2 and 4 do not match. If the circumference C2 of the second gravure cylinder 4 exceeds the circumference C1 of the first gravure cylinder 2, the pattern repeat length of the second gravure cylinder 4 exceeds the pattern repeat length of the first gravure cylinder 2. As a result, the elements printed on the second gravure cylinder 4 will be shifted relative to the pattern repeat portion of the first gravure cylinder 2.

[0122] An example in which the pattern is a wood grain pattern will be described below. However, in other examples, the pattern may also be any type of pattern, such as a stone grain pattern, a brick pattern, an imaginary pattern, and the like.

[0123] The first gravure cylinder 2 can print a first pattern. The first pattern can represent a main pattern. The first pattern can be a wood grain pattern. The first pattern can include one or more patterns that form a pattern repeating portion. The second gravure cylinder 4 can print a second print. The second gravure cylinder 4 can print additional elements on the first print. The additional elements can be wood grains, knots and / or medullary rays. The additional elements can add elements to the main pattern. Since the circumference C2 of the second gravure cylinder 4 is different from the circumference C1 of the first gravure cylinder 2, these elements will be printed at different positions relative to the first pattern printed by the first gravure cylinder 2. As a result, the print provided by the combination of the first gravure cylinder 2 and the second gravure cylinder 4 will not repeat, as will be referred to in detail. Figure 3A -C further described.

[0124] In the above, rotary gravure printing has been described with reference to the first gravure cylinder 2 and the second gravure cylinder 4, but it will be understood by those skilled in the art that the process is repeated for each color forming the print. Each color forming the print is applied by a separate gravure cylinder. The first gravure cylinder 2 can be regarded as representing a group of first gravure cylinders 2 applying a first pattern, wherein these first gravure cylinders 2 each have a circumference C1. The second gravure cylinder 4 can be regarded as representing a group of second gravure cylinders 4 applying a second pattern, wherein these second gravure cylinders 4 each have a circumference C2.

[0125] As a reference Figure 1 Alternatively or in addition to the examples described, digital printing can be combined with rotogravure printing, as described in reference Figure 2 as described.

[0126] exist Figure 2 In the above reference Figure 1 The polymer base film 1 of the type described is printed by a first rotogravure cylinder 2 having a circumference C1. The first rotogravure cylinder 2 may correspond to the above referenced Figure 1 The first rotary gravure cylinder 2 or the second rotary gravure cylinder 4.

[0127] In addition to rotogravure printing, the polymer base film 1 can also be printed by digital printing methods, for example by Figure 2 Inkjet printing disclosed in .

[0128] Compared to rotogravure printing, where each individual design requires a separate engraving of the gravure cylinder 2, digital printing offers a more flexible printing process. An example of a digital printing method is inkjet printing using an inkjet printer 7, which Figure 2 It is schematically shown in FIG.

[0129] In one example of inkjet printing, the polymer base film 1 to be printed is transported under a number of print bars 8a-e. The print bars 8a-e may extend transversely to the transport direction or the printing direction. The print bars 8a-e may each include a number of inkjet print heads. The inkjet print heads eject ink droplets onto the substrate.

[0130] The polymer base film 1 may be printed by digital printing after rotogravure printing, or vice versa.

[0131] The first gravure cylinder 2 may print a main pattern, such as a wood grain pattern, and the inkjet printing method prints additional elements, such as wood grain, knots and / or medullary rays, onto the main pattern. The additional elements may be printed by digital printing to avoid pattern repetition of the polymer base film 1. Although the pattern printed by the first gravure cylinder 2 may be repeated on the polymer base film 1, the additional elements printed by digital printing increase the elements, thereby avoiding the overall pattern of the polymer base film 1 from including a repetitive portion.

[0132] Figure 3A -C shows an example of a portion of a printed polymer base film 1 . Figure 3A A first pattern 11 is shown. Figure 3A The first pattern 11 shown in the figure can form a main pattern. The first pattern 11 can be made by referring to the above Figure 2 The first gravure cylinder is printed.

[0133] In the length direction of the printed polymer base film 1, the polymer base film 1 is printed with a pattern, namely a first pattern 11. In this example, the pattern repeating portion contains only a single pattern. The length of the pattern in the length direction of the polymer base film 1 corresponds to the pattern repeating length R1. The pattern repeating length R1 substantially corresponds to the circumference C1 of the first gravure cylinder used to print the pattern.

[0134] Figure 3A The illustrated first pattern 11 may include wood elements, such as wood grain, knots and / or medullary rays.

[0135] exist Figure 3A , only a portion of the print of the polymer base film 1 is shown in the width direction of the polymer base film 1. The width of the print on the polymer base film 1 may be substantially the same as the width of the polymer base film 1. Therefore, only a portion of the first pattern 11 is shown in the width direction of the printed polymer base film 1. The first pattern 11 and the second pattern 12 described below may be regarded as representing a set of first patterns and a set of second patterns in the width direction of the printed polymer base film 1, respectively.

[0136] The first pattern 11 may be repeated in the length direction of the polymer base film 1 .

[0137] Figure 3B The second pattern 12 is shown. The second pattern 12 can be referred to above Figure 1 The second gravure cylinder 4 described is printed. The second pattern 12 may include design elements, such as wood grain, knots and / or medullary rays. In this example, the pattern repeat portion contains only a single pattern. The length of the pattern in the length direction of the polymer base film 1 corresponds to the pattern repeat length R2. The pattern repeat length R2 substantially corresponds to the circumference C2 of the second gravure cylinder 4 used to print the pattern.

[0138] like Figure 3A and 3B As shown, the pattern repeat length R2 of the second pattern 12 exceeds the pattern repeat length R1 of the first pattern 11 .

[0139] Figure 3C The combination of the first pattern 11 and the second pattern 12 on the polymer base film 1 is shown. Since the pattern repeat length L2 of the second pattern 12 exceeds the pattern repeat length R1 of the first pattern 11, the overall pattern formed by the first pattern 11 and the second pattern 12 does not repeat over the length of the polymer base film 1. The second pattern 12 adds elements to the first pattern 11, thereby preventing the first pattern 11 from being completely repeated on the polymer base film 1.

[0140] If the second pattern 12 is printed by digital printing, the second pattern 12 may not be repeated on the polymer base film 1. In other words, the pattern repeat length R2 may substantially correspond to the length of the polymer base film. The elements printed by digital printing may be adapted to the pattern of the first pattern 11 to avoid repetition. The elements may be printed by digital printing to reduce the visual impression that the first pattern 11 is repeated.

[0141] The first pattern 11 may be formed by a first set of design elements, such as Figure 3A The first set of design elements can form a main pattern. The second pattern 12 can be formed by a second set of design elements, such as Figure 3B The second set of design elements may form additional elements, such as holes, cracks and / or medullary rays. The first set of design elements and the second set of design elements together form a combined pattern, such as Figure 3A -C.

[0142] Figure 4 A continuous process for forming a laminate substrate is shown. The layers of the laminate substrate may be applied and bonded in-line in the process.

[0143] exist Figure 4 In the process shown, the substrate 10 is produced in an extrusion process by an extruder 16 or a co-extruder. Thus, the substrate 10 is an extruded substrate. The substrate 10 is formed in a continuous process.

[0144] The substrate 10 may have a rectangular shape, for example, with a length greater than a width.

[0145] The substrate 10 may include a polymer-based material. The polymer-based material may be a thermoplastic or thermosetting material. The polymer-based material may be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The substrate 10 may include 10-60 wt % of the polymer material.

[0146] The substrate 10 may further include fillers. The fillers may be organic fillers and / or inorganic fillers. The organic fillers may be wood chips, crushed rice husks, cork, bamboo chips. The inorganic fillers may be calcium carbonate, chalk, limestone, talc, stone chips, fly ash. The substrate 10 may include 30-90 wt% of the fillers.

[0147] The substrate 10 may also include additives, such as impact modifiers, stabilizers, lubricants, pigments, foaming agents, and / or plasticizers. The substrate 10 may also include pigments.

[0148] In one example, the substrate 10 may include 10-30 wt% PVC, 50-90 wt% chalk, and 0-20 wt% additives. Such a substrate 10 may be of the type generally referred to as SPC.

[0149] The feed rate for a continuous process including the extruder 16 or a co-extruder may be 0.5-12 m / min, such as 1-10 m / min or 1.5-9.0 m / min.

[0150] The barrel temperature of the extruder 16 may be 145-225° C. When extruding PVC, the barrel temperature of the extruder 16 may be 145-225° C. Alternatively or additionally, the extrudate temperature immediately after molding may be 90-280° C. When the substrate 10 comprises PVC, the extrudate temperature may be 90-225° C., preferably 145-220° C.

[0151] The substrate 10 may be calendered by passing it through one or more calendering rollers 17a, 17b so that the substrate 10 obtains a desired thickness. After calendering, the thickness of the substrate 10 may be 2-10 mm. Alternatively or additionally, the substrate 10 may be pressed to a desired thickness.

[0152] The feed rate of the continuous process comprising the extruder 16 or co-extruder and the calender roll arrangement 17a, 17b may be 0.5-12 m / min, such as 1-10 m / min or 1.5-9.0 m / min.

[0153] After calendering, the substrate 10 may be fed onto a roller 32 .

[0154] After calendering, the above reference Figure 1 , 2 The printed polymer base film 1 described in and 3A-C is applied to the first surface of the substrate 10. The polymer base film 1 can be obtained by referring to the above reference Figure 1 The printing can be carried out by rotary gravure printing as described above, or by the above-referenced Figure 2 The printing is carried out by a combination of rotogravure printing and digital printing as described.

[0155] The printed polymer base film 1 may be applied continuously on the substrate 10 .

[0156] The printed polymer base film 1 may be applied to the substrate 10 before the substrate 10 is cooled.

[0157] The printed polymer base film 1 may be applied to the substrate 10 such that the length direction of the printed polymer base film 1 is substantially parallel to the length direction of the substrate 10 .

[0158] exist Figure 4 In the embodiment of the present invention, a protective layer 18 is applied to the printed polymer base film 1. The protective layer 18 can be a protective film, such as a polymer base film. The polymer material of the protective film can be a thermoplastic or thermosetting material. The polymer base film can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0159] The thickness of the protective layer 18 may be 0.1-2 mm.

[0160] Optionally, a backing layer (not shown) may be applied to a second surface of the substrate 10 , opposite the printed polymer base film 1 .

[0161] The substrate 10, the printed polymer base film 1 and optionally the protective layer 18 and the backing layer are attached to each other by applying pressure, for example in a pressing and embossing device 30. Figure 4 In the example shown, the pressing and embossing device 30 comprises rollers 31 and 32. Heat may also be applied during pressing.

[0162] After applying pressure by rollers 31 and 32, a laminated substrate 20 is obtained. The laminated substrate 20 includes the substrate 10 and the printed polymer base film 1. The laminated substrate 20 may optionally further include a protective layer 18 and a backing layer.

[0163] In the pressing and embossing device 30, an embossed structure is imparted to the laminated base material 20 by an embossing roller 31. The embossing roller 31 is configured to emboss the laminated base material 20 with the embossed structure.

[0164] The pressing roller 32 may apply a counter pressure to the second surface of the substrate 10 opposite to the printed polymer base film 1 .

[0165] The embossing roller 31 is engraved with an embossing structure. The embossing roller 31 has a circumference C3. The embossing roller 31 has an embossing structure engraved on its circumferential surface.

[0166] The embossing roller 31 may have a rotation axis that may be arranged parallel to the width direction of the printed polymer base film 1. The embossing roller 31 may have a length extension direction parallel to the width direction of the printed polymer base film 1. The embossing roller 31 may have a rotation axis that is substantially transverse to the length direction of the polymer base film 1.

[0167] The embossing roller 31 may have a rotation axis that is substantially parallel to the rotation axes of the first and second intaglio cylinders 2 and 4 .

[0168] The polymer base film 1 has been prepared as described above. Figure 1 In the example of printing by rotary gravure printing, the circumference C3 of the embossing roller may substantially correspond to the circumference C1 of the first gravure cylinder 2, or the circumference C2 of the second gravure cylinder 4. For example, the circumference C3 of the embossing roller may differ from the circumference C1 of the first gravure cylinder 2 or the circumference C2 of the second gravure cylinder 4 by less than 5 mm, such as less than 3 mm, such as less than 1 mm.

[0169] If the circumference C3 of the embossing roller 31 and the embossed structure correspond to the circumference C1 and the engraved pattern of the first gravure cylinder 2, the embossed structure may be aligned or at least partially aligned with the first pattern 11 printed by the first gravure cylinder 2. The pattern 11 printed by the first gravure cylinder 2 may be a main pattern, so that the embossed structure is aligned or at least partially aligned with the main pattern.

[0170] The embossed structure may be out of alignment with the second pattern 12 formed by the second gravure cylinder 4, or at least not completely aligned.

[0171] As mentioned above Figure 3A As described above, the first pattern 11 may include a first set of design elements. The embossed structure may be aligned or at least partially aligned with the first set of design elements. The embossed structure may not be aligned, or at least not completely aligned, with the second set of design elements of the second pattern 12 formed by the second gravure cylinder 4.

[0172] In another example, the circumference C3 of the embossing roller 31 and the embossing structure may correspond or substantially correspond to the circumference C2 and the engraved pattern of the second gravure cylinder 4, and the embossing structure may be aligned or at least partially aligned with the second pattern 12 printed by the second gravure cylinder 4. The second pattern 12 printed by the second gravure cylinder 4 may be a main pattern, so that the embossing structure is aligned or at least partially aligned with the main pattern.

[0173] The embossed structure may be out of alignment with the first pattern 11 formed by the first gravure cylinder 2, or at least not completely aligned.

[0174] As mentioned above Figure 3A -C, the second pattern 12 may include a second set of design elements. The embossed structure may be aligned with the second set of design elements, or at least partially aligned. The embossed structure may not be aligned with the first set of design elements of the first pattern 11 formed by the first gravure cylinder 2, or at least not completely aligned.

[0175] If the polymer base film 1 is printed by a combination of rotary gravure printing and digital printing, as described above with reference to Figure 2 As described above, the circumference C3 of the embossing roller may substantially correspond to the circumference C1 of the first gravure cylinder 2 .

[0176] If the circumference C3 of the embossing roller 31 and the embossed structure correspond to the circumference C1 and the engraved pattern of the first gravure cylinder 2, the embossed structure may be aligned or at least partially aligned with the first pattern 11 printed by the first gravure cylinder 2. The pattern 11 printed by the first gravure cylinder 2 may be a main pattern, so that the embossed structure is aligned or at least partially aligned with the main pattern.

[0177] As mentioned above Figure 3A As described above, the first pattern 11 may include a first set of design elements. The embossed structure may be aligned with the first set of design elements, or at least partially aligned with the first set of design elements.

[0178] A digital printing process (eg, inkjet printing) may print a second set of design elements that form a second pattern 12, as described above with reference to FIG. Figure 2 The embossed structure may not be aligned, or at least not completely aligned, with the second set of design elements of the second pattern 12 printed by digital printing.

[0179] In another example, the circumference C3 of the embossing roller 31 and the embossing structure may correspond to the pattern and pattern repeat length R2 of the second pattern 12, so that the embossing structure is aligned or at least partially aligned with the second pattern 12. The second set of design elements 12 forming the second pattern 12 may be aligned or at least partially aligned with the embossing structure.

[0180] After embossing, an embossed laminate substrate 20 may be obtained. The laminate substrate 20 may be further divided into a plurality of panels, which will be referred to as Figure 6-8 Give a description.

[0181] Figure 5 An example of a continuous process similar to the process in Figure 3 is shown. Figure 5 In the process, the arrangement of rollers and Figure 4 In all other respects, the above Figure 4 The public content also applies to Figure 4 In the example. Figure 5 In the embodiment, after extrusion, the substrate 10 of the above type is calendered by passing it through one or more calendering rollers 17a, 17b so that the substrate 10 obtains the desired thickness. The substrate 10 is then fed to roller 17c. A printed polymer base film 1 of the above type and an optional protective layer 18 are applied to the substrate 10 and fed between rollers 17c and 17d.

[0182] As described above, the substrate 10, the printed polymer base film 1 and the optional protective layer 18 and the backing layer are attached to each other by applying pressure, for example in a pressing and embossing device 30. Figure 5 In the example shown, the pressing and embossing device 30 comprises rollers 31 and 32. Heat may also be applied during pressing.

[0183] After pressure has been applied by rollers 31 and 32, a laminated substrate 20 is obtained. The laminated substrate 20 comprises the substrate 10 and the printed polymer base film 1. The laminated substrate 20 may optionally further comprise a protective layer 18 and a backing layer.

[0184] In the pressing and embossing device 30, an embossed structure is imparted to the laminated base material 20 by an embossing roller 31. The embossing roller 31 is configured to emboss the laminated base material 20 with the embossed structure.

[0185] The pressing roller 32 may apply a counter pressure on the second surface of the substrate 10 opposite to the printed polymer base film 1 .

[0186] The embossing roller 31 is engraved with an embossing structure. The embossing roller 31 has a circumference C3. The embossing roller 31 has an embossing structure engraved on its circumferential surface. The embossing roller 31 may correspond to Figure 4 The embossing roller 31 in FIG. Figure 4 The public content also applies to Figure 5 The embossing roller in the.

[0187] Figure 6 Another example of a process for forming a laminate substrate is shown. Figure 6 In the process shown, a substrate 10' is provided. The substrate 10' may have been formed in a previous process. The substrate 10' may have been pressed, for example, by calendering a number of layers which together form the substrate 10'.

[0188] The substrate 10' may include a polymer-based material. The polymer-based material may be a thermoplastic or thermosetting material. The polymer-based material may be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The substrate 10' may include 10-60 wt% of the polymer material.

[0189] The substrate 10' may further comprise a filler. The filler may be organic and / or inorganic. The organic filler may be wood chips, crushed rice husks, cork, bamboo chips. The inorganic filler may be calcium carbonate, chalk, limestone, talc, stone chips, fly ash. The substrate 10 may comprise 30-90 wt% of the filler. The substrate 10' may comprise 30-90 wt% of the filler.

[0190] The substrate 10' may also contain additives, such as impact modifiers, stabilizers, lubricants, pigments, foaming agents and / or plasticizers. The substrate 10 may also contain pigments.

[0191] The thickness of the substrate 10 ′ may be 2-10 mm.

[0192] In one example, the substrate 10 may contain 10-30 wt% PVC, 50-90 wt% chalk, and 0-20 wt% additives. Such a substrate 10 may be of the type generally referred to as SPC.

[0193] The printed polymer base film 1 is applied to the first surface of the substrate 10. The polymer base film 1 can be printed by rotary gravure printing, as described above with reference to Figure 1 Alternatively, it may be printed by a combination of rotary gravure printing and digital printing, as described above with reference to Figure 2 described.

[0194] The printed polymer-based film 1 may be applied to the substrate 10 ′ such that the length direction of the printed polymer-based film 1 is substantially parallel to the length direction of the substrate 10 ′.

[0195] exist Figure 6In the embodiment of the present invention, a protective layer 18 is applied to the printed polymer base film 1. The protective layer 18 can be a protective film, such as a polymer base film. The polymer material of the protective film can be a thermoplastic or thermosetting material. The polymer base film can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0196] The thickness of the protective layer 18 may be 0.1-2 mm.

[0197] Optionally, a backing layer (not shown) may be applied to a second surface of the substrate 10 ′, opposite the printed polymer base film 1 .

[0198] The substrate 10 ′, the printed polymer base film 1 and optionally the protective layer 18 and the backing layer are attached to one another by applying pressure, for example in an embossing and pressing device 30 . Figure 5 In the example shown, the pressing device 30 comprises a double belt press 33, 34. Heat may also be applied during pressing.

[0199] The upper belt 33 of the double belt press is provided with an embossed structure, thereby forming an embossed belt, so that pressing and embossing are performed in one process step.

[0200] After passing through the pressing device 30, a laminated substrate 20 is obtained, which includes the substrate 10' and the printed polymer base film 1. The laminated substrate 20 may optionally further include a protective layer 18 and a backing layer. The laminated substrate 20 has an embossed structure.

[0201] exist Figure 6 In the example shown, embossing is performed simultaneously with pressing to form the laminate substrate 20 .

[0202] The embossed structure of the upper pressing belt 33 is configured to emboss the laminate substrate 20 with the embossed structure. The uppermost layer may be a polymer base film 1 which has been printed.

[0203] The embossed pressed belt 33 forming the embossed belt has a circumference C4. The embossed pressed belt 33 is engraved with an embossed structure. The circumference C4 of the embossed pressed belt 33 forming the embossed belt is engraved with an embossed structure. The peripheral surface of the embossed pressed belt 33 can be defined as the surface length intended to be in contact with the uppermost layer of the laminated substrate 20.

[0204] The embossed pressed tape 33 has a lengthwise extension direction parallel to the lengthwise direction of the printed polymer base film 1 .

[0205] The polymer base film 1 is as described above Figure 1 In the example of performing rotogravure printing, the circumference C4 of the embossing pressing belt 33 may substantially correspond to the circumference C1 of the first gravure cylinder 2 , or the circumference C2 of the second gravure cylinder 4 .

[0206] If the circumference C4 of the embossed pressed belt 33 and the embossed structure correspond to the circumference C1 and the pattern of the first gravure cylinder 2, the embossed structure may be aligned, or at least partially aligned, with the first pattern 11 printed by the first gravure cylinder 2. The pattern 11 printed by the first gravure cylinder 2 may be a main pattern, so that the embossed structure is aligned, or at least partially aligned, with the main pattern.

[0207] The embossed structure may be out of alignment with the second pattern 12 formed by the second gravure cylinder 4, or at least not completely aligned.

[0208] As mentioned above Figure 3A As described above, the first pattern 11 may include a first set of design elements. The embossed structure may be aligned with the first set of design elements, or at least partially aligned. The embossed structure may not be aligned with the second set of design elements of the second pattern 12 formed by the second gravure cylinder 4, or at least not completely aligned.

[0209] In another example, the circumference C4 and the embossed structure of the embossed pressed belt 33 may correspond to the circumference C2 and the pattern of the second gravure cylinder 4, and the embossed structure may be aligned or at least partially aligned with the second pattern 12 printed by the second gravure cylinder 4. The second pattern 12 printed by the second gravure cylinder 4 may be a main pattern, so that the embossed structure is aligned or at least partially aligned with the main pattern.

[0210] The embossed structure may be out of alignment with the first pattern 11 formed by the first gravure cylinder 2, or at least not completely aligned.

[0211] As mentioned above Figure 2 As described above, the second pattern 12 may include a second set of design elements. The embossed structure may be aligned with the second set of design elements, or at least partially aligned. The embossed structure may not be aligned with the first set of design elements of the first pattern 11 formed by the first gravure cylinder 2, or at least not completely aligned.

[0212] If the polymer base film 1 is printed by a combination of rotary gravure printing and digital printing, as described above with reference to Figure 2 As described above, the circumference C4 of the embossing pressing belt 33 may substantially correspond to the circumference C1 of the first gravure cylinder 2 .

[0213] If the circumference C4 of the embossed pressed belt 33 and the embossed structure correspond to the circumference C1 and the pattern of the first gravure cylinder 2, the embossed structure is aligned or at least partially aligned with the first pattern 11 printed by the first gravure cylinder 2. The pattern 11 printed by the first gravure cylinder 2 may be a main pattern, so that the embossed structure is aligned or at least partially aligned with the main pattern.

[0214] As mentioned above Figure 3A As described above, the first pattern 11 may include a first set of design elements. The embossed structure may be aligned with the first set of design elements, or at least partially aligned with the first set of design elements.

[0215] A digital printing process (eg, inkjet printing) can print a second set of design elements that form a second pattern 12, as described above with reference to FIG. Figure 2 The embossed structure may not be aligned, or at least not completely aligned, with the second set of design elements of the second pattern 12 printed by digital printing.

[0216] In another example, the circumference C4 of the embossed pressed band 33 and the embossed structure may correspond to the pattern and pattern repeat length R2 of the second pattern 12, such that the embossed structure is aligned or at least partially aligned with the second pattern 12. The second set of design elements 12 forming the second pattern 12 may be aligned or at least partially aligned with the embossed structure.

[0217] After embossing, an embossed laminate substrate 20 is obtained. The laminate substrate 20 can be further divided into a plurality of panels, which will be referred to as Figure 7-9 Give a description.

[0218] After embossing, a coating (not shown) may be applied to the printed polymer film 1 or, if a protective layer 18 has already been applied, to the protective layer 18 .

[0219] Figure 7 An example of a laminate substrate 20 seen from above after pressing and embossing is shown. The laminate substrate 20 comprises a substrate 10; 10' and a printed polymer base film 1. The laminate substrate 20 may be referred to above with reference to Figure 4-6 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Figure 7 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Figure 7 In the example shown, the length L1 exceeds the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0220] The laminate substrate 20 is intended to be divided into a plurality of panels which are Figure 7The laminate substrate 20 is divided into a plurality of panels, for example by sawing. The panels may also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distances required to divide the laminate substrate 20 into the individual panels and / or the distances required to machine the mechanical locking system along the panel edges may be taken into account.

[0221] These panels can be tiles or laths. Figure 7 In the example shown, the panels are in the form of strips, ie the length L2 is greater than the width W2. Figure 7 In the example shown, the length direction of the strips is substantially parallel to the length direction of the laminate substrate 20. Each panel may have an equal length L2 and an equal width W2.

[0222] exist Figure 7 In the example shown, the laminate substrate 20 is intended to be divided into 10 panels P11, P12, P13, P14, P15, P21, P22, P23, P24, P25. Figure 7 In the embodiment, the laminate substrate 20 is intended to be divided into panels arranged in a first row of panels P11, P12, P13, P14, P15 along the length direction of the laminate substrate 20, and panels arranged in a second row of panels P21, P22, P23, P24, P25 after the first row of panels.

[0223] In one example, the width of the panel may be 178 mm and the length may be 1219 mm (7 x 48”). If the substrate 10 is extruded in an extruder having a width of about 1 m, five panels having a width of 178 mm may be provided side by side in the width direction of the substrate 10, such as Figure 7 shown. Figure 6 The panels shown may be 1219 mm in length.

[0224] If an extruder having a width of about 1.3 m is used to extrude the substrate 10, 7 panels having a width of 178 mm can be provided side by side in the width direction of the substrate 10. Accordingly, such a laminated substrate can be intended to be divided into 14 panels.

[0225] In another example, the panel may be 305mm wide and 610mm long (12x24").

[0226] In other examples, the panels may be 229 mm wide and 1524 mm long (9 x 60"). In still other examples, the panels may be tiles that are 457 mm wide and 457 mm long (18 x 18").

[0227] The laminated substrate 20 is intended to be divided into panels whose length corresponds substantially to the circumference of the embossing means, either in the form of an embossing roller 31 having a circumference C3 or in the form of an embossing pressing belt 33 having a circumference C4.

[0228] If the circumference C3 , C4 of the embossing device corresponds to the circumference C1 of the first intaglio cylinder 2 , the length of the panel will substantially correspond to the length R1 of the first pattern 11 .

[0229] If the circumference C3 , C4 of the embossing device corresponds to the circumference C2 of the second intaglio cylinder 2 or the pattern repeat length of the digitally printed pattern, the length of the panel will substantially correspond to the length R2 of the second pattern 12 .

[0230] Since the lengths of the first pattern 11 and the second pattern 12 are different, the patterns of the panels will not be the same. Thus, the number of different panels obtained from the substrate will increase.

[0231] In one example, the first pattern 11 forms the main pattern. The first pattern 11 can be printed by a first gravure cylinder 2 having a circumference C1. The length of each panel corresponds to the circumference C1 of the first gravure cylinder 2. The length of each panel can correspond to the length of the first pattern 11. Thus, each panel has the first pattern 11. In addition to the first pattern 11, the second pattern 12 also adds certain design elements to the first pattern 11. Since the second pattern is printed by a second gravure cylinder 4 having a circumference C2 (which exceeds the circumference C1 of the first gravure cylinder 2), the repeating portion of the second pattern 12 does not overlap with the repeating portion of the first pattern 11. Thus, the combined pattern of each panel will be unique.

[0232] As an alternative, the second set of design elements may be printed by digital printing, thereby avoiding any repetition of the second pattern 12.

[0233] exist Figure 7 In the example shown, 10 panels with different patterns are obtained. In the known solutions, only 5 panels with different patterns can be obtained.

[0234] The embossed structure may be aligned with at least a portion of the panel pattern, or at least partially aligned.As described above, the panel pattern may be aligned with at least the first pattern or the second pattern.

[0235] Figure 8 A second example of a laminated substrate 20 is shown as seen from above after pressing and embossing. The laminated substrate 20 comprises a substrate 10; 10' and a printed polymer base film 1. The laminated substrate 20 may be referred to above with reference to Figure 4-6 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Figure 8 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Figure 8 In the example shown, the length L1 exceeds the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0236] The laminate substrate 20 is intended to be divided into a plurality of panels which are Figure 8 The laminate substrate 20 is divided into a plurality of panels, for example by sawing. The panels may also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distance required to divide the laminate substrate 20 into individual panels and / or the distance required to machine the mechanical locking system along the panel edges may be taken into account.

[0237] These panels can be tiles or laths. Figure 8 In the example shown, the panels are in the form of strips, ie the length L2 is greater than the width W2. Figure 8 In the example shown, the length direction of the strips is substantially parallel to the length direction of the laminate substrate 20. Each panel may have an equal length L2 and width W2.

[0238] exist Figure 8 In the example shown, the laminate substrate 20 is intended to be divided into 20 panels P11, P12, P13, P14, P15, P21, P22, P23, P24, P25, P31, P32, P33, P34, P35, P41, P42, P43, P44, P45. Figure 8 In the embodiment, the laminate substrate 20 is intended to be divided into panels arranged as follows: a first row of panels including panels P11, P12, P13, P14, P15, a second row of panels including panels P21, P22, P23, P24, P25, a third row of panels including panels P31, P32, P33, P34, P35, and a fourth row of panels including panels P41, P42, P43, P44, P45. The rows of panels are arranged one after another in the length direction of the laminate substrate 20.

[0239] In one example, the width of the panel may be 178 mm and the length may be 1219 mm (7 x 48 "). If the substrate 10 is extruded in an extruder with a width of about 1 m, five panels with a width of 178 mm may be provided side by side in the width direction of the substrate 10, such as Figure 8 shown.

[0240] If an extruder having a width of about 1.3 m is used to extrude the substrate 10, 7 panels having a width of 178 mm can be provided side by side in the width direction of the substrate 10. Accordingly, such a laminated substrate can be intended to be divided into 28 panels.

[0241] In another example, the panel may be 305mm wide and 610mm long (12x24").

[0242] In other examples, the panels may be 229 mm wide and 1524 mm long (9 x 60"). In still other examples, the panels may be tiles that are 457 mm wide and 457 mm long (18 x 18").

[0243] The laminated substrate 20 is intended to be divided into panels whose length corresponds substantially to the circumference of the embossing means, either in the form of an embossing roller 31 having a circumference C3 or in the form of an embossing pressing belt 33 having a circumference C4.

[0244] If the circumference C3 , C4 of the embossing device corresponds to the circumference C1 of the first intaglio cylinder 2 , the length of the panel will substantially correspond to the length R1 of the first pattern 11 .

[0245] If the circumference C3 , C4 of the embossing device corresponds to the circumference C2 of the second intaglio cylinder 2 or the pattern repeat length of the digitally printed pattern, the length of the panel will substantially correspond to the length R2 of the second pattern 12 .

[0246] Since the lengths of the first pattern 11 and the second pattern 12 are different, the patterns of the panels will be different. Thus, the number of different panels obtained from the substrate will be increased.

[0247] In one example, the first pattern 11 forms the main pattern. The first pattern 11 can be printed by a first gravure cylinder 2 having a circumference C1. Each panel has the first pattern 11. The length of each panel corresponds to the circumference C1 of the first gravure cylinder 2. The length of each panel can correspond to the length of the first pattern 11. Thus, each panel has the first pattern 11.

[0248] In addition to the first pattern 11, the second pattern 12 also adds some design elements to the first pattern 11. Since the second pattern is printed by the second gravure cylinder 4 having a circumference C2 (which is greater than the circumference C1 of the first gravure cylinder 2), the repeating part of the second pattern 12 does not coincide with the repeating part of the first pattern 11, so that the combined pattern of each panel will be unique.

[0249] As an alternative, the second set of design elements may be printed by digital printing, thereby avoiding any repetition of the second pattern 12 .

[0250] exist Figure 8 In the example shown, 20 panels with different patterns are obtained. In the known solution, only 5 panels with different patterns can be obtained.

[0251] The embossed structure may be aligned with at least a portion of the panel pattern, or at least partially aligned.As described above, the panel pattern may be aligned with at least the first pattern or the second pattern.

[0252] Fig. 9 A second example of a laminated substrate 20 is shown as seen from above after pressing and embossing. The laminated substrate 20 comprises a substrate 10; 10' and a printed polymer base film 1. The laminated substrate 20 may be referred to above with reference to Figure 4-6 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Fig. 9 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Fig. 9 In the example shown, the length L1 exceeds the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0253] The laminate substrate 20 is intended to be divided into a plurality of panels which are Fig. 9 The laminate substrate 20 is divided into a plurality of panels, for example by sawing. The panels may also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distance required to divide the laminate substrate 20 into individual panels and / or the distance required to machine the mechanical locking system along the panel edges may be taken into account.

[0254] These panels can be tiles or laths. Fig. 9 In the example shown, the panels are in the shape of tiles, ie their length L2 is substantially the same as their width W2. Each panel may have an equal length L2 and an equal width W2.

[0255] exist Fig. 9 In the example shown, the laminate substrate 20 is intended to be divided into eight tiles P11, P12, P21, P22, P31, P32, P41, P42. Fig. 9 In the embodiment, the laminate substrate 20 is intended to be divided into tiles arranged as follows: a first row of tiles including tiles P11 and P12, a second row of tiles including tiles P21 and P22, a third row of tiles including tiles P31 and P32, and a fourth row of tiles including tiles P41 and P42. The rows of tiles are arranged successively to each other in the length direction of the laminate substrate 20.

[0256] In one example, the tiles may be 457 mm (18 x 18") wide and long tiles.

[0257] The laminate substrate 20 is intended to be divided into tiles whose length corresponds substantially to the circumference C3; C4 of the embossing device 30, which is in the form of an embossing roller 31 with a circumference C3, or an embossing pressing belt 33 with a circumference C4. Alternatively, the length of the tile may correspond to a portion of the circumference C3; C4 of the embossing device 30.

[0258] If the circumference C3 , C4 of the embossing means corresponds to the circumference C1 of the first intaglio cylinder 2 , the length of the tile will substantially correspond to the length R1 of the first pattern 11 .

[0259] If the circumference C3 , C4 of the embossing device corresponds to the circumference C2 of the second intaglio cylinder 2 or the pattern repeat length of the digitally printed pattern, the length of the panel will substantially correspond to the length R2 of the second pattern 12 .

[0260] If the polymer-based film 1 is printed by the first gravure cylinder 2 or the second gravure cylinder 4 having a pattern repeat including more than one pattern, the length of the tile may correspond to the length of each individual pattern in the pattern repeat.

[0261] Since the lengths of the first pattern 11 and the second pattern 12 are different, the patterns of the panels will be different. Thus, the number of different panels that can be obtained from the substrate will increase.

[0262] In one example, the first pattern 11 forms the main pattern. The first pattern 11 can be printed by a first gravure cylinder 2 having a circumference C1. Each panel has the first pattern 11. In addition to the first pattern 11, the second pattern 12 adds certain design elements to the first pattern 11. Since the second pattern is printed by a second gravure cylinder 4 having a circumference C2 (which is greater than the circumference C1 of the first gravure cylinder 2), the repeating part of the second pattern 12 does not overlap with the repeating part of the first pattern 11, so that the combined pattern of each panel will be unique.

[0263] As an alternative, the second set of design elements may be printed by digital printing, thereby avoiding any repetition of the second pattern 12.

[0264] exist Fig. 9 In the example shown, 8 tiles with different embossed structures are obtained. In the known solution, only 2 tiles with different embossed structures can be obtained.

[0265] References in the above Figure 7-9In one example of a panel described, a polymer base film 1 is printed by a first gravure cylinder 2, thereby forming a first pattern 11. The polymer base film 1 is printed by a second gravure cylinder 4, thereby forming a second pattern 12. The circumference C2 of the second gravure cylinder 4 exceeds the circumference C1 of the first gravure cylinder 2. The circumferences C3; C4 of the embossing device correspond to the circumference C1 of the first gravure cylinder 2. The embossed structure of the embossing device is aligned with the pattern of the first gravure cylinder 2. The length of the panel corresponds to the circumference C1 of the first gravure cylinder 2.

[0266] In the above disclosure the panels may be contemplated as building panels such as floor panels, furniture components, countertops, wall panels, ceiling panels.

[0267] List of entries:

[0268] Item 1. A method for producing a laminate substrate (20) having an embossed structure, comprising:

[0269] A polymer base film (1) is provided, which has a first pattern (11) printed by at least one first gravure cylinder (2) and a second pattern (12) printed by digital printing,

[0270] applying the polymer-based film (1) to a substrate (10; 10') comprising a polymer-based material,

[0271] pressing the polymer-based film (1) onto the substrate (10; 10') to form a laminated substrate (20), and

[0272] The laminated substrate (20) is embossed by an embossing device (30) so that the laminated substrate (20) obtains an embossed structure, wherein the circumference (C3; C4) of the embossing device (30) corresponds to the circumference (C1) of the first gravure cylinder (2), or corresponds to the pattern repeat length (R2) of the second pattern (12).

[0273] Item 2. A method according to Item 1, wherein the circumference (C3; C4) of the embossing device (30) corresponds to the circumference (C1) of the first gravure roller (2), so that the first pattern (11) formed by the first gravure roller (2) is at least partially aligned with the embossed structure.

[0274] Item 3. A method according to Item 2, wherein the second pattern (12) formed by digital printing is not aligned with the embossed structure, or at least not completely aligned.

[0275] Item 4. A method according to any of the preceding items, wherein the first pattern (11) comprises a first set of design elements and the second pattern (12) comprises a second set of design elements, wherein the embossed structure is aligned with the first set of design elements.

[0276] Item 5. A method according to Item 1, wherein the circumference (C3; C4) of the embossing device (30) corresponds to the pattern repeat length (R2) of the second pattern (12), so that the second pattern (12) formed by digital printing is aligned with the embossed structure.

[0277] Item 6. The method according to Item 5, wherein the first pattern (11) formed by the first gravure cylinder (2) is not aligned, or at least not completely aligned, with the embossed structure.

[0278] Item 7. A method according to Item 5 or 6, wherein the first pattern (11) comprises a first set of design elements and the second pattern (12) comprises a second set of design elements, wherein the embossed structure is aligned with the second set of design elements.

[0279] Item 8. The method according to any one of the preceding items, wherein the first pattern (11) and / or the second pattern (12) is a wood grain pattern.

[0280] Item 9. Method according to any of the preceding items, wherein the first pattern (11) adds at least one knot, crack and / or at least one medullary ray to the second pattern (12), or vice versa.

[0281] Item 10. The method according to any of the preceding items, further comprising dividing the laminate substrate (20) into a plurality of panels, wherein the length (L2) of the panels substantially corresponds to the circumference (C4; C4) of the embossing device (30).

[0282] Item 11. The method according to any of the preceding items, wherein the substrate (10; 10') is formed by a continuous process.

[0283] Item 12. The method according to any one of the preceding items, wherein the polymer-based film (1) is applied continuously to the substrate.

[0284] Item 13. The method according to any one of the preceding items, wherein the substrate (10; 10') is formed by extrusion.

[0285] Item 14. The method according to any one of the preceding items, further comprising applying a protective layer to the polymer base film (1) prior to embossing.

[0286] Item 15. The method according to any one of the preceding items, wherein pressing comprises applying heat and pressure.

[0287] Item 16. The method according to any one of the preceding items, wherein the substrate (10; 10') further comprises a filler, the filler being one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, sawdust, crushed rice husk, cork, bamboo chips.

[0288] Item 17. The method according to any one of the preceding items, wherein the polymer-based film (1) is a PVC film.

Claims

1. A method for producing a laminated substrate (20) having an embossed structure, the method comprising: A polymer base film (1) is provided which is printed by at least a first gravure cylinder (2) forming a first pattern (11) and a second gravure cylinder (4) forming a second pattern (12), wherein the circumference (C2) of the second gravure cylinder (4) is greater than the circumference (C1) of the first gravure cylinder (2), The polymer-based film (1) is applied to a substrate (10; 10') comprising a polymer-based material, pressing the polymer-based film (1) onto the substrate (10; 10') to form a laminated substrate (20), and The laminated substrate (20) is embossed by an embossing device (30) so that the laminated substrate (20) obtains an embossed structure, wherein the circumference (C3; C4) of the embossing device (30) corresponds to the circumference (C1) of the first gravure cylinder (2) or corresponds to the circumference (C2) of the second gravure cylinder (4).

2. The method according to claim 1, wherein: The circumference (C3; C4) of the embossing device (30) corresponds to the circumference (C1) of the first gravure cylinder (2), so that the first pattern (11) formed by the first gravure cylinder (2) is at least partially aligned with the embossed structure.

3. The method according to claim 2, wherein: The second pattern (12) formed by the second gravure cylinder (4) is not aligned, or at least not completely aligned, with the embossed structure.

4. A method according to any one of the preceding claims, wherein: The first pattern (11) comprises a first set of design elements and the second pattern (12) comprises a second set of design elements, wherein the embossed structure is aligned with the first set of design elements.

5. The method according to claim 1, wherein: The circumference (C3; C4) of the embossing device (30) corresponds to the circumference (C2) of the second gravure cylinder (4), so that at least a portion of the second pattern (12) formed by the second gravure cylinder (4) is aligned with the embossed structure.

6. The method according to claim 5, wherein: The first pattern (11) formed by the first gravure cylinder (2) is not aligned, or at least not completely aligned, with the embossed structure.

7. The method according to claim 5 or 6, wherein: The first pattern (11) comprises a first set of design elements and the second pattern (12) comprises a second set of design elements, wherein the embossed structure is aligned with the second set of design elements.

8. A method according to any one of the preceding claims, wherein: The first pattern (11) and / or the second pattern (12) is a wood grain pattern.

9. A method according to any one of the preceding claims, wherein: The first pattern (11) adds at least one knot, crack and / or medullary ray to the second pattern (12), or the second pattern (12) adds at least one knot, crack and / or medullary ray to the first pattern (11).

10. The method according to any of the preceding claims, further comprising dividing the laminate substrate (20) into a plurality of panels, wherein the length (L2) of a panel substantially corresponds to the circumference (C3; C4) of the embossing device (30).

11. A method according to any one of the preceding claims, wherein: The substrate (10; 10') is formed by a continuous process.

12. A method according to any one of the preceding claims, wherein: The polymer-based film (1) is applied continuously on the substrate (10; 10').

13. A method according to any one of the preceding claims, wherein: The substrate (10; 10') is formed by extrusion.

14. The method according to claim 13, wherein: The polymer-based film (1) is applied to the substrate (10; 10') before cooling the substrate (10; 10').

15. The method according to any one of the preceding claims, further comprising applying a protective layer to the polymer base film (1) prior to embossing.

16. A method according to any one of the preceding claims, wherein: Pressing involves the application of heat and pressure.

17. A method according to any one of the preceding claims, wherein: The substrate (10; 10') contains a filler, which is one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, wood chips, crushed rice husks, cork, bamboo chips.

18. A method according to any one of the preceding claims, wherein: The polymer-based film (1) is a PVC film.

Images