System for manufacturing substrates with decorative design

Abstract

The invention relates to a system for manufacturing a substrate (1) having a decorative design (3), such as an image and / or relief, comprising a feed device (10; 90), a digital printing device (5, 40) for printing a decorative design (3) on the foil (2), and a covering device (30; 30 ') for covering the substrate (1) with the foil (2); 50, 51). The system is designed to be used for feeding the feed device (10; 90) and after the foil material (2) is supplied by means of the covering device (30; the digital printing device (5, 40) prints the foil material (2) before covering the substrate (1) with the digital printing device (5, 40).

Description

[0001] This application is a divisional application of the invention patent application with application number 202111201546.X filed on October 15, 2021 and the invention name “System for manufacturing a substrate with a decorative design”. Technical Field

[0002] The present invention relates to a system for manufacturing a substrate, such as a panel or a profile, incorporating a decorative design, such as an image and / or a relief, as a surface finish adapted to the particularities of the substrate.

[0003] The invention relates in particular to the covering of substrates by foil or layer materials. The invention is particularly suitable for use in building and furniture products such as furniture panels, doors and floors, door and window frame profiles and the like. Background Art

[0004] At present, systems are known for applying decorative designs formed by images and / or reliefs provided on a foil covering a substrate. In these systems, the foil is provided with a decorative design incorporated therein, the panels or profiles are then covered with the foil and bonded to each other by means of an adhesive applied between the foil and the substrate.

[0005] Today's requirements increasingly require continuous production of substrates with sparsely repeated decorative designs. This forces a change in the foil feed or continuous foil feed reel in order to replace the printed foil with the respective desired decorative design and to obtain a variety of decorative designs produced by the same system.

[0006] An exemplary method for manufacturing a printed product can be found in EP2329954A1.

[0007] The present invention aims to provide a system for manufacturing a substrate with a decorative design, which system is able to obtain substrates with various decorative designs in a universal manner. Summary of the invention

[0008] In order to solve the above objects, besides providing additional advantages which will be mentioned below, the present invention provides a system for producing a substrate with a decorative design, such as an image and / or a relief, comprising a feeding device for feeding a foil, a digital printing device, in particular an inkjet printing device, of the decorative design on the foil, and a covering device for covering the substrate with the foil.

[0009] According to the invention, the system is configured for printing the foil with a digital printing device after feeding the foil to the feeding device and before covering the substrate with the covering device. The incorporation of the digital printing device in the system makes it possible to obtain substrates with various decorative designs in a universal manner, thereby allowing the desired printing to be selected for each foil covering the respective substrate.

[0010] In this way, the substrate can be given any desired appearance or even the decorative design can be changed without the need to change the feed reel or the foil. Likewise, it enables various surfaces of the substrate to be covered (completely or partially), such as the upper side, the lateral edges, the lower side, even complex surfaces, etc., with different decorative designs for different selected surface areas.

[0011] This ability to provide different decorative designs on the same foil increases the flexibility in performing the covering, for example, being able to provide foils with different decorative designs for different sides of a substrate, particularly the top and edges of a panel, or to provide continuity of decorative design between different sides, etc.

[0012] The feeding device for feeding foil according to the invention can be configured for feeding foil continuously, for example by means of a foil feeding reel. Alternatively, the feeding device for feeding foil can be configured for feeding foil discontinuously, for example using a foil-by-foil feeding device.

[0013] It is envisaged that the system according to the invention comprises a processing unit functionally connected to the digital printing device, such that the processing unit is configured for printing different decorative designs for different substrates and / or foils. The processing unit is configured to print different decorative designs depending on physical characteristics of the substrate and / or foil, such as size, shape, material, surface roughness, etc. Thus, it is possible to provide different decorative designs for different substrates in a flexible manner and in real time.

[0014] According to the invention, it is envisaged that physical features of the substrate and / or foil can be detected, for example, by scanning or sensing the substrate and / or foil or by instructions received in the processing unit. To this end, the system can incorporate a scanner or sensor, for example, to directly detect physical features of the substrate and / or foil or to detect markings or logos of the substrate and / or foil.

[0015] The system according to the invention may further comprise an application device for applying adhesive, so as to apply adhesive on the substrate and / or foil so that the substrate and / or foil are bonded together by the adhesive after covering. The application device for applying adhesive may be, for example, by a lip, a roller, spraying, digital printing, in particular inkjet, etc.

[0016] Alternatively or additionally, it is also conceivable that the foil can be supplied at least partially pre-glued.

[0017] Preferably, it is envisaged that the processing unit is functionally connected to the application device for applying the adhesive and is thereby configured for applying different adhesive quantities depending on physical characteristics of the substrate and / or the foil, such as size, shape, material, surface roughness, etc. This enables a more flexible manufacturing of substrates with decorative designs depending on different physical characteristics of the substrate and / or the foil and thus of the decorative design.

[0018] According to the invention, the covering device can be configured for shaping the foil on the substrate surface so that the foil is adapted to the shape of the substrate.

[0019] The invention also envisages that the system according to the invention may comprise a first digital printing device for an image and a second digital printing device for a relief, the system being configured so that the first device and the second device print the respective image and the relief synchronously with each other. Thus, a relief corresponding to the image may be obtained, enabling, for example, the texture or tactile surface of a natural material such as wood or stone to be imitated or replicated. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The following drawings have been included as part of the explanation of at least one practical embodiment of the invention.

[0021] Figure 1 A schematic diagram of a first embodiment of a system according to the invention is shown.

[0022] Figure 2 A schematic diagram of a second embodiment of the system according to the invention is shown, wherein, unlike the first embodiment, covering the substrate with the foil comprises shaping the foil.

[0023] Figure 3 A schematic diagram of a first variant of the first embodiment of the system according to the invention is shown, wherein the adhesive application is achieved by digital inkjet printing instead of by a lip.

[0024] Figure 4 A schematic diagram of a second variant of the first embodiment of the system according to the invention is shown, in which the adhesive application is effected by a roller instead of by a lip.

[0025] Figure 5 A schematic diagram of a third embodiment of the system according to the invention is shown, wherein, unlike the first embodiment, the adhesive application is carried out both to the foil and to the substrate.

[0026] Figure 6 A schematic diagram of a first variant of a third embodiment of the system according to the invention is shown, wherein the application of adhesive to the foil is effected by a lip rather than by digital inkjet printing.

[0027] Figure 7A schematic diagram of a second variant of the third embodiment of the system according to the invention is shown, wherein application of adhesive to the foil is achieved by a lip rather than by digital inkjet printing and application of adhesive to the substrate is achieved by a roller rather than by digital inkjet printing.

[0028] Figure 8 A schematic diagram of a fourth embodiment of the system according to the invention is shown, in which, unlike the previous embodiments, the foil feeding is performed discontinuously, that is to say foil by foil and not via a continuous feed reel.

[0029] Fig. 9 A schematic diagram showing sequential steps of an exemplary embodiment of a process for manufacturing a substrate having a decorative design that can be performed by a system according to the present invention. DETAILED DESCRIPTION

[0030] The system uses a substrate (1) as a base product which is covered with a foil (2) on which a personalized decorative design is applied "in situ" in a continuous process using a digital inkjet printing device (5, 40). Thus, a substrate (1) covered with a printed foil (2) is obtained, which is provided with a surface finish having a decorative design (3). Thus, depending on the decorative design (3) of the covering foil used, the substrate (1), such as a panel or a profile, can be given any desired appearance.

[0031] The substrate (1) can be made of various materials, such as wood derivatives (particleboard, medium density fiberboard "MDF", high density fiberboard "HDF" or plywood), plastic materials (PVC), cellulose-based materials (paper or cardboard), metal materials, etc. The foil (2) can be made of paper, PVC, HPL, CPL, etc.

[0032] The digital inkjet printing device (5, 40) comprises at least one digital inkjet print head (5) and a digital printing curing or drying device (40) for curing and / or drying the printed ink producing the decorative design.

[0033] The feeding device (10; 90) for feeding the foil (2) can be continuous (10) or discontinuous (90). Figures 1 to 7 In an embodiment of the present invention, the foil (2) is continuously fed from a feed reel (10) and thereby guided to the covering portion of the substrate (1) by at least one guide roller (20, 60). Figure 8 In the embodiment of the present invention, the foils (2) are fed discontinuously from the foil stack (90), ie, foil by foil.

[0034] It is conceivable that, for applying the adhesive (4), the system comprises means for applying the adhesive (6; 7, 70; 8, 9; 11, 80; 12, 13), which is configured to apply the adhesive (4) to the substrate (1) and / or the foil (2) to be bonded together after covering. The application of the adhesive (4) can be carried out before or after the digital printing. In a variant of the system shown in the figure, the application of the adhesive (4) is carried out after the application of the decorative design (3). However, according to the invention, it is also conceivable that, alternatively or additionally, it can be carried out before the decorative design is applied.

[0035] A covering device (30; 50, 51) for covering a substrate (1) with a foil (2) comprises a pressure roller (30) for spreading the foil (2) on the surface of the substrate (1) so that the foil (2) covers the surface of the substrate (1), in particular a flat surface. Figure 2 In an embodiment of the present invention, the covering device (30; 50, 51) further comprises a forming roller system (50, 51) for forming the foil (2) on the surface of the substrate (1), in this case so that the foil (2) is folded over the lateral edges of the substrate (1), but it can be configured so that the foil (2) covers surfaces of the substrate (1) that are inclined relative to each other or complex surfaces. By applying pressure with the covering device (30; 50, 51), bonding between the substrate (1) and the foil (2) is achieved.

[0036] like Figure 1 As shown, a continuous foil (2) is fed from a feed reel (10) by guide rollers (20), a decorative design (3) is executed on the foil (2) by a digital inkjet print head (5), and then cured or dried by a digital print curing or drying device (40).

[0037] Adhesive (4) is applied to the foil (2) with the decorative design (3) by means of an adhesive applicator lip (6) and once the adhesive (4) has been applied, the printed foil (2) already coated with glue is attached to the substrate (1) by pressing the foil (2) against the substrate (1) with the aid of a pressure roller (30) so as to cover it, thus obtaining a completely homogeneous final product.

[0038] Figure 1 The embodiment shown is not limiting since, as can be seen from the different figures, many variations exist depending on the components used and their placement in the system.

[0039] Therefore, in Figure 2 In the exemplary embodiment of , the above is followed by a forming stage by means of a forming roller system (50, 51). Thus, the foil (2) covers the substrate (1), adapting to the shape of the substrate (1) so that both the front surface and the edges are covered by the foil (2).

[0040] The forming roller system (50, 51) consists of a system of longitudinal pressure tools (usually wheels with different characteristics) which form, post-form or profile the foil (2) on the substrate (1) in the direction of advancement towards the substrate to be covered. Other strategically positioned elements can be used to adhere the foil (2) to the substrate, adapting the foil to the shape of the substrate (1) until it obtains its final shape at the end of the process, thus integrating with the substrate (1).

[0041] Similarly, in Figure 3 In an embodiment of the invention, after digital inkjet printing, adhesive (4) is applied to the foil (2) after the foil (2) has been guided by two consecutive foil guide rollers (20 and 60). In this variant, the application of the adhesive (4) is performed by means of an adhesive digital inkjet print head (7), whereby subsequent curing or drying is performed by means of an adhesive curing or drying device (70) before applying a rotating pressure roller (30) in the advancing direction towards the substrate (1).

[0042] also, Figure 4 The embodiment of follows the same process, but the adhesive (4) is applied to the foil (2) by an applicator roller (8) in cooperation with an adhesive dosing roller (9) for dosing a certain amount of adhesive (4) on the applicator roller (8) by relative rotation and movement between the applicator roller (8) and the dosing roller (9).

[0043] Likewise, in Figures 5 to 7 In the embodiment of the system shown, the adhesive (4) is applied to the foil (2) and / or substrate (1) using a variation on the application of the adhesive (4) by means of a digital printing step of a decorative design (3) by means of a digital inkjet print head (5) followed by subsequent curing or drying using a digital print curing or drying device (40). Figure 5 In the method, the adhesive (4) is applied to the foil (2) by a digital inkjet print head (7) and also to the substrate (1) by a digital inkjet print head (11), and in both cases is subsequently cured by an adhesive curing or drying device (70; 80) before applying a pressure roller (30).

[0044] and Figure 5 Different, in Figure 6 In the embodiment of the present invention, the adhesive (4) is applied to the foil (2) by means of the lip (6) without undergoing subsequent curing, and once the adhesive (4) has been applied, it is pressed against the substrate (1) by means of a pressure roller (30). Figure 7 Shown with Figure 6 Embodiments of the invention are different embodiments in which the adhesive (4) is applied to the substrate (1) by an applicator roller (12) in cooperation with a dosing roller (13).

[0045] Figure 8 Represents a process wherein feed material or foil (2) is supplied discontinuously from a foil stack (90) and only adhesive (4) is applied to a substrate (1) by a digital inkjet print head (7) followed by subsequent curing with an adhesive curing or drying device (70).

[0046] As adhesive curing or drying device (40) or digital printing device (70, 80), for example, electromagnetic radiation, UV, IR or electronic lamps or drying by hot air can be used.

[0047] According to the invention, the system may comprise supplementary means for preparing the substrate (1) and / or the foil (2), such as means for priming the substrate (1) and / or the foil (2), a protective layer for the foil (2), a base layer for embossing on the foil (2), means for removing material from a mixture of droplets ejected by inkjet to emboss on the foil (2), etc. Fig. 9 The following steps are shown of a possible process that may be performed using the system according to the present invention:

[0048] a) Applying a primer to the foil.

[0049] b) Curing the primer.

[0050] c) Application of decorative designs by inkjet.

[0051] d) Curing or semi-curing the print.

[0052] e) Applying a protective layer to the printed layer.

[0053] f) Curing or semi-curing the protective layer.

[0054] g) Applying a base layer of liquid material in which the embossing is to take place.

[0055] h) ejecting material droplets by inkjet for mixing with the liquid material layer.

[0056] I) Curing process of the mixture and the remaining materials.

[0057] j) Removal of mixed material by mechanical means.

[0058] k) Applying a layer of finishing material.

[0059] l) Curing the finishing layer.

[0060] It is also possible to use a substrate (1) and / or foil (2) that has been previously prepared to receive the decorative design (3) and / or the adhesive (4), so that, for example, no primer needs to be applied. It is also possible to have a pre-glued foil (2), which would prevent the adhesive (4) from being applied to the foil (2) during the process.

[0061] The system can advantageously be implemented to replicate different decorative designs on a foil (2) for covering a substrate (1) in a continuous process or without changing the reel (10) or sheet (90).

Claims

1. A system for producing a substrate (1) having a decorative design (3), such as an image and / or a relief, the system comprising - a feeding device (10; 90) for feeding the foil (2), - a digital printing device (5, 40) for printing said decorative design (3) on said foil (2), and - covering means (30; 50, 51) for covering the substrate (1) with the foil (2), The system is configured to print the foil (2) by means of the digital printing device (5, 40) after the foil (2) is fed by means of the feeding device (10; 90) and before the substrate (1) is covered by means of the covering device (30; 50, 51). It is characterized in that The system comprises a processing unit functionally connected to the digital printing device (5, 40), wherein the processing unit is configured to print different decorative designs (3) for different substrates (1) and / or foils (2) depending on the physical characteristics of the substrate (1) and / or the foil (2).

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

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

4. System for producing a substrate (1) according to one of claims 1 to 3, wherein: The covering device (30; 50, 51) is designed to shape the foil (2) on the surface of the substrate (1) so that the foil (2) adapts to the shape of the substrate (1).

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

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