METHOD FOR PRODUCING A DECORATED WALL OR FLOOR PANEL

Description

[0001] The present invention relates to a method for producing a decorated wall or floor panel.

[0002] Such decorated panels are known per se, although the term "wall panel" also includes panels suitable for ceiling cladding. They typically consist of a carrier or core made of a solid material, such as a wood-based panel, which is coated on at least one side with a decorative layer and a cover layer, as well as optionally with additional layers, such as a wear layer arranged between the decorative and cover layers. The decorative layer is typically a printed paper impregnated with an aminoplast resin. The cover layer and the other layers are also usually made of aminoplast resin.

[0003] A method for manufacturing a panel is known from document US Pat. No. 6,888,147 B1. In one method known from this document, a decorative element is applied to a core, after which the decorative element is coated with a lacquer layer.

[0004] WO 2015 / 128255 A1 discloses a method for producing a decorative panel. In this method, a lacquer-containing top layer is partially cured, forming a curing gradient, with the curing gradient extending along the thickness of the top layer. The top layer is then structured and finally cured. Partial and final curing can be carried out using different wavelengths.

[0005] However, in certain areas of application and particularly where stable and easy-to-manufacture panels are required, the processes known from the state of the art still offer potential for improvement.

[0006] It is therefore the object of the present invention to provide an improved method for producing decorated wall or floor panels.

[0007] This object is achieved by a method according to claim 1. Preferred embodiments of the invention are described in the subclaims, in the description or the figures, wherein further features described or shown in the subclaims or in the description or the figures can individually or in any combination constitute an object of the invention, unless the context clearly indicates the opposite.

[0008] The invention thus proposes a method for producing a decorated wall or floor panel, comprising the following process steps: a) Providing a plate-shaped carrier, b) Applying a decoration simulating a decorative template to at least a partial area of ​​the plate-shaped carrier, c) Applying a cover layer to the decoration, wherein the cover layer comprises a radiation-curing compound, and d) Curing the cover layer, wherein the cover layer is cured using a first radiator and a second radiator, wherein the first radiator emits radiation with a different wavelength compared to the second radiator and wherein the first radiator and the second radiator are used in a common curing step without further intermediate steps,wherein process step b) is carried out by a digital printing process and process step c) is carried out at least partially by a digital printing process and wherein, to form the cover layer (40), at least initially a first layer (40') is applied to the decoration (32) and then a structure-containing layer (40'') is applied by means of a digital printing device (50), to which layer a finishing layer (56) is applied by means of an application unit (54) and then the curing takes place according to step d).

[0009] The method described above offers significant advantages over state-of-the-art solutions.

[0010] The method described above thus serves to form a decorated wall or floor panel. The term "decorated wall or floor panel" or "decorative panel" in the context of the invention refers in particular to wall, ceiling, door, or floor panels that feature a decoration applied to a carrier plate. Decorative panels are used in a variety of ways, both in the interior design of rooms and for the decorative cladding of buildings, for example, in trade fair construction. One of the most common applications for decorative panels is their use as floor coverings. The decorative panels often feature a decoration intended to replicate a natural material.

[0011] Examples of such simulated natural materials include wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge, and even exotic woods such as panga-panga, mahogany, bamboo, and bubinga. In addition, natural materials such as stone or ceramic surfaces are often simulated.

[0012] The method described above comprises, according to method step a), providing a plate-shaped support. A "plate-shaped support" within the meaning of the present invention can be understood as a natural material, such as a wood-based material, a fiber material, or a material comprising a plastic, which is in the form of a plate and can serve, in particular, as the core or base layer of the panel to be produced. For example, the plate-shaped support can already impart suitable stability to the panel or contribute to this stability. Furthermore, the plate-shaped support can already predetermine the shape and / or size of the panel to be produced. However, the plate-shaped support can also be provided as a large plate.A large panel within the meaning of the invention is in particular a carrier whose dimensions exceed the dimensions of the final decorative panels by several times and which is divided into a corresponding plurality of decorative panels during the manufacturing process, for example by sawing, laser or water jet cutting.

[0013] For example, a substrate can be made from a natural material, a plastic, or a wood-plastic composite (WPC). Layered structures made from several of the aforementioned materials can also be used, such as plasterboard or wood-plastic laminated panels.

[0014] For example, the carrier plate can be made of a thermoplastic, elastomer, or thermosetting plastic. Mineral plates such as natural and artificial stone plates, concrete plates, gypsum fiber plates, so-called WPC plates (made from a mixture of plastic and wood), as well as plates made from natural raw materials such as cork and wood can also be used as carriers according to the invention. Plates made from biomass as a natural material such as straw, corn stalks, bamboo, leaves, algae extracts, hemp, and oil palm fibers can also be used according to the invention. Furthermore, recycled materials made from the aforementioned materials can be used within the scope of the inventive method. Furthermore, the plates can be based on the natural material cellulose, such as paper or cardboard.

[0015] Wood-based materials within the meaning of the invention include, in addition to solid wood materials, materials such as cross-laminated timber, glued laminated timber, block laminated timber, veneer plywood, laminated veneer lumber, veneer strip lumber, and bending plywood. Furthermore, wood-based materials within the meaning of the invention also include wood particle materials such as chipboard, extruded boards, oriented structural boards (OSB), and chipboard strip lumber, as well as wood fiber materials such as wood fiber insulation boards (HFD), medium-hard and hard fiberboards (MB, HFH), and, in particular, medium-density fiberboards (MDF) and high-density fiberboards (HDF).Modern wood-based materials such as wood-polymer materials (WPC), sandwich panels made of a lightweight core material such as foam, rigid foam, or paper honeycomb with a wood layer applied thereon, as well as mineral-bonded particle boards, for example, with cement, also constitute wood-based materials within the meaning of the invention. Cork also constitutes a wood-based material within the meaning of the invention.

[0016] For the purposes of the invention, the term fiber materials refers to materials such as paper and nonwovens based on plant, animal, mineral, or even artificial fibers, as well as cardboard. Examples of fiber materials made from plant fibers include paper and nonwovens made from cellulose fibers, as well as panels made from biomass such as straw, corn stalks, bamboo, leaves, algae extracts, hemp, cotton, or oil palm fibers. Examples of animal fiber materials include keratin-based materials such as wool or horsehair. Examples of mineral fiber materials include materials made from mineral wool or glass wool.

[0017] Furthermore, the carrier can be a plastic-based carrier, i.e., it can comprise or consist of a plastic. Examples of thermoplastics are polyvinyl chloride, polyolefins (e.g., polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK), or mixtures or copolymers thereof. The plastics can contain conventional fillers, for example, calcium carbonate (chalk), aluminum oxide, silica gel, quartz powder, wood flour, or gypsum. They can also be colored in a known manner. In particular, the carrier material can contain a flame retardant.

[0018] Thermoplastics, in particular, offer the advantage that the products made from them can be easily recycled. Recycled materials from other sources can also be used. This provides another opportunity to reduce manufacturing costs.

[0019] It may be preferred if the carrier is a plastic-containing carrier comprising a carrier material with a plastic-containing matrix material, into which a solid material, in particular with a particle size of less than or equal to 600 µm, is embedded. It may further be preferred for the matrix material to comprise polypropylene, for example in the form of LDPE, wherein the polypropylene may comprise a mixture of a homopolymer and a copolymer. With regard to the distribution of homopolymer and copolymer, it may be preferred that the homopolymer is present in a proportion of ≥ 10 wt.% to ≤ 40 wt.%, for example in a proportion of ≥ 20 wt.% to ≤ 30 wt.%, for example in a proportion of ≥ 23 wt.% to ≤ 28 wt.%, based on the polypropylene, and / or that the copolymer is present in a proportion of ≥ 60 wt.% to ≤ 90 wt.%, for example in a proportion of ≥ 70 wt.% to ≤ 80 wt.%, for example in a proportion of ≥ 72 wt.% to ≤ 76 wt.%.-%, in particular wherein the polypropylene consists of the homopolymer and the copolymer.

[0020] The solid can be, for example, a wood-based material such as wood flour, or another material such as a component of the rice plant, such as the rice husk, the rice stalk and the rice husk, cellulose or a mineral material such as rock flour, chalk or other inorganic mineral materials. It can be particularly preferred if the solid is formed from talc, for example consists thereof. In principle, the solids can be in the form of chips, shavings, flour or fibers. With regard to the use of talc as a solid, it can be advantageous that high stability can be enabled, especially in this embodiment. Furthermore, such a carrier material can enable improved moisture resistance, in particular with reduced moisture- or heat-induced swelling.In a manner known per se, talc is understood to mean a magnesium silicate hydrate, which may, for example, have the chemical formula Mg 3 [Si 4 O 10 (OH) 2 ].

[0021] In a particularly preferred embodiment, it can be advantageous that the solid material is formed by talc to an extent of at least 50% by weight, based on the solid material, wherein the matrix material is present in an amount, based on the carrier material, of ≥ 30% by weight to ≤ 70% by weight, for example of ≥ 35% by weight to ≤ 42% by weight, and wherein the solid material, based on the carrier material, is present in an amount, based on the carrier material, of ≥ 30% by weight to ≤ 80% by weight, for example of ≥ 65% by weight to ≤ 73% by weight, and wherein the carrier material and the solid material together are present in an amount of ≥ 95% by weight, based on the carrier material.

[0022] In principle, such a carrier can be provided or formed as is known for decorative panels. For example, the carrier can be provided from a granular starting material, which is pressed under pressure and temperature into a corresponding plate-shaped carrier, whereby this example is in no way limiting.

[0023] Furthermore, the method according to method step b) comprises applying a decoration simulating a decorative template to at least a partial area of ​​the plate-shaped carrier.

[0024] A "decorative template" in the present context can be understood, in particular, as an original natural material or at least a surface of such a material that is to be imitated or recreated by the decoration. The decoration can be applied, for example, by applying a printed paper or an unprinted or partially printed paper, which is then printed. Alternatively, the decoration can be printed directly onto the carrier or a suitable printing substrate, as described below.

[0025] To apply a decoration, a decorative substrate can first be applied to at least a portion of the carrier. For example, a primer, particularly for printing processes, can first be applied as a decorative substrate, for example in a thickness of ≥ 10 µm to ≤ 60 µm. The primer can be a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, a radical scavenger, a flow control agent, a defoamer or preservative, a pigment, and / or a dye.

[0026] In addition to the use of a primer, it is possible to apply the decoration to a decorative paper that can be printed with a corresponding decoration. This decorative paper can be provided as a bonding agent, for example, by means of a resin layer previously applied to the carrier. Furthermore, a resin can be applied to the paper as a printing substrate. This resin can have at least one compound selected from the group consisting of melamine resin, formaldehyde resin, urea resin, phenolic resin, epoxy resin, unsaturated polyester resin, diallyl phthalate or mixtures thereof as a resin component. In the process according to the invention, the primer can preferably be applied to the carrier plate by means of rubber rollers, a casting machine or by spraying. The primer is preferably applied in an amount between ≥1 g / m 2< and ≤100 g / m 2< , preferably between ≥10 g / m 2< and ≤50 g / m 2< , in particular between ≥20 g / m 2< and ≤40 g / m 2<.After the primer has been applied to the carrier surface, it is irradiated with a radiation source of a suitable wavelength.

[0027] Alternatively or in addition to the primer, for example onto the primer, a primer can also be applied directly onto the carrier or onto the primer. For a decorative image of particularly high visual quality, for example, a white-colored primer can be applied, which can contain white color pigments, for example. For example, the primer can be applied in two layers. It can be particularly preferred for the primer to be radiation-curable, for example UV-curable. In this case, a first layer of primer can preferably be cured before the application of a further layer of primer and / or before the decoration is printed. For example, the primer can comprise polyurethane, for example in the form of a polyurethane varnish, and can be provided with white pigments.

[0028] According to a further embodiment of the method, the decoration or decorative layer can be applied by direct printing. The term "direct printing" in the context of the invention refers to the application of a decoration directly onto the support of a panel or onto an unprinted fiber material layer applied to the support. In contrast to conventional methods, in which a previously printed decorative layer is applied to a support, in direct printing the decoration is printed directly during panel production. Various printing techniques can be used, such as flexographic printing, offset printing, or screen printing. However, according to the invention, digital printing techniques such as inkjet printing or laser printing are used.

[0029] The aforementioned printing processes are particularly sophisticated and advantageously suited for panel production, allowing for the application of a detailed decoration identical to the original. For the purposes of the invention, direct printing also includes the application of the decoration using printing techniques to a printable layer previously applied to the substrate. Such a printable layer can be formed, for example, by a liquid-applied and subsequently cured primer layer or a previously applied printable film, paper, or nonwoven layer.

[0030] In the digital printing process according to the invention, the three-dimensional decorative data are provided in electronic form or in digital form.

[0031] This can apply, for example, to data stored in a database as well as to data acquired in-situ by a three-dimensional scanner. Thus, the provided decorative data, particularly through digital printing processes, can be used directly without any further intermediate steps, making the process particularly cost-effective and easy to implement, especially in this embodiment. Furthermore, the use of digital printing processes makes it possible to execute each printing process individually, thus enabling a particularly wide range of applications and dynamic adaptation to the desired product.

[0032] The decorative layer or decoration can be formed from a particularly radiation-curable paint and / or ink. For example, a UV-curable paint or ink can be used.

[0033] Furthermore, if necessary, the substrate may be pretreated to remove electrostatic charge, for example, prior to printing. This can be particularly useful to prevent blurring during the decorative application process.

[0034] According to a further embodiment of the method, the decorative layers or the decoration can each be applied in a thickness in a range of ≥ 5 µm to ≤ 10 µm. For example, the decorative layers can each be applied in a thickness in a range of 8 µm. In particular in this embodiment or with such thicknesses of the individual decorative layers, a particularly template-identical impression of the decoration or the panel can be achieved through a particularly thin design of the decorative layers and thus extremely precise variability of the surface application or the coverage of a layer by the respectively applied decorative layer.

[0035] Subsequently, according to process step c), a cover layer is applied to the decoration, wherein the cover layer comprises a radiation-curing compound. A protective or cover layer can be understood in particular as a layer that protects underlying layers from wear and which can also serve to accommodate a structure. In particular, a plurality of cover layers are provided on the decoration to protect it. The design of the cover layers is described in detail below.

[0036] The top layer can comprise an acrylate-based lacquer. In particular, the top layer can comprise one or more acrylates, which can be modified, in particular, with polyurethane (PU), or acrylate / polyurethane systems can be used. Furthermore, it can be provided that the top layer is used as a lacquer, for example, as a radiation-curable or at least partially radiation-curable composition, for example, based on an epoxy lacquer or a urethane acrylate.

[0037] Such coating systems, in particular, can form a particularly scratch- and impact-resistant top layer, which can make the decorative panel to be produced particularly durable. The present invention, in particular, makes it possible to provide such coating systems with a negative structuring, thus enabling a particularly high-quality structural impression while retaining the advantages of the coating layer.

[0038] The cover layer can, for example, have a layer thickness between ≥ 100µm and ≤ 5mm, preferably between ≥ 0.5mm and ≤ 2.5µm.

[0039] For example, it can be provided that two cover layers are provided, or that the cover layer is designed in two layers. The layers can be made of the same material, in particular varnish, or of different materials, such as in particular from different varnishes. In an embodiment not according to the invention, a lower protective layer can have a structure and the upper protective layer can cover the lower protective layer. In this embodiment, it can be provided that the lower layer has a comparatively higher viscosity when applied in order to be able to keep structures stable even before hardening, and / or that the upper layer has a comparatively low viscosity in order to be able to form a uniform finish. Furthermore, it can be provided that the lower layer has a greater thickness than the upper layer.For example, the lower layer, which can serve as a structural coating, can be applied in a quantity of ≥ 30 g / m 2< to ≤ 40 g / m 2<, whereas the upper layer, which can serve as a topcoat, can be applied in a quantity of ≥ 10 g / m 2< to ≤ 15 g / m 2<.

[0040] It can be provided that the cover layer contains hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures thereof in order to increase the wear resistance of the layer. It can be provided that the hard material is contained in the wear layer composition in an amount between 5 wt.% and 40 wt.%, preferably between 15 wt.% and 25 wt.%. The hard material preferably has an average grain diameter between 10 µm and 250 µm, more preferably between 10 µm and 100 µm. This advantageously ensures that the cover layer composition forms a stable dispersion and demixing or settling of the hard material in the wear layer composition can be avoided.

[0041] To form a corresponding cover layer, one embodiment may provide for the radiation-curable composition containing the hard material to be applied in a concentration of between 10 g / m 2 and 250 g / m 2 , preferably between 25 g / m 2 and 100 g / m 2 . The application may be carried out, for example, by means of rollers, such as rubber rollers, or by means of casting devices.

[0042] It can be provided that the hard material is not contained in the composition at the time of application of the top layer composition, but is scattered as particles onto the applied top layer composition and this is subsequently hardened by radiation.

[0043] In general, a structure, particularly a surface structure matching the decor, can be introduced into the cover layer by introducing pores, which is also referred to as synchronous pores. This can be achieved, for example, through so-called negative structuring, in which the cover layer is provided with a structure using an embossing tool, such as an embossing stamp or an embossing roller, by pressing the structure into the cover layer. For this purpose, the cover layer can first be partially cured, then provided with a structure, and then finally cured.

[0044] When forming the top layer with lacquers, the structure can also be introduced through so-called positive structuring, in which the structures are built up by applying a lacquer layer, particularly by selectively applying the raised areas of the structure. This is often achieved using negatively structured embossing media, which can apply the lacquer layer accordingly.

[0045] According to the invention, positive structuring is achieved by printing a structure, for example, by optionally applying a multi-layer coating. Process step c) is carried out at least partially by a digital printing process.

[0046] In this embodiment, a structure can be applied in a particularly advantageous manner. By printing a structure, it can be applied with the utmost precision and, particularly advantageously, as a synchronous pore in accordance with the decoration. For this purpose, appropriate three-dimensional decoration data can be used, for example, to print the decoration in order to achieve a visual appearance with a corresponding tactile structure that is as identical as possible or almost identical to a decoration template. Printing can be carried out using an inkjet printer or a laser printer, for example.

[0047] According to the invention, the structure is not printed directly onto the decoration, but at least one, for example two, further layers of the cover layer or protective layer are arranged below the structure layer.

[0048] This layer or layers can be applied in a conventional manner, for example, by roller application or similar. It may be possible to cure the individual layers beneath the structure, for example, using second emitters, as described in detail with its configurations, before the structure is printed. For example, a first layer of an abrasion-resistant layer can be applied, this can be cured, and a further abrasion-resistant layer can be applied and cured before the structure is printed. The abrasion-resistant layers or cover layers can be provided with abrasion-resistant particles, as described above.

[0049] In principle, it can be provided that the top layer, and thus individual, several or all layers of the top layer, are provided with abrasion-resistant particles.

[0050] Before applying the abrasion-resistant layers, a primer can be applied to the decor. For example, a UV-curable primer can be applied. A UV-curing coating system, such as an acrylate-based coating system, can be used as the primer.

[0051] The printed structure of the cover layer can also be cured using multiple beam units. Curing with different wavelengths in a single curing step can be particularly advantageous, as it allows for particularly fast and effective curing, which can be beneficial with regard to the stability of the printed structure and thus the long-term stability and abrasion resistance of the produced panel. For example, the structure can be printed using multiple layers, with each layer being cured before the application of a subsequent layer.

[0052] According to the invention, a finishing layer is applied to the printed structure.

[0053] This layer can, in turn, be formed by a varnish, such as an acrylic varnish, which can be applied using conventional methods. This final layer can further improve the stability of the layered structure and also enhance the appearance of the structure.

[0054] In principle, it can be provided that all layers above the decoration are UV-curable and are cured before the application of a further layer, in particular using a plurality of emitters or a plurality of wavelengths, as described in detail elsewhere. Thus, all of these layers can be cured in one curing step, i.e., in a continuous curing step using different wavelengths. Furthermore, individual or all of the layers can contain abrasion-resistant particles.

[0055] This makes it possible to easily and with high precision create a surface texture that matches the decorative image without any additional steps. A surface texture that matches the decorative image means that the surface of the decorative panel has a tactile structure whose shape and pattern correspond to the appearance of the applied decoration, thus achieving the most faithful reproduction of a natural material, including its haptics.

[0056] In the method described above, the cover layer is cured using a first emitter and a second emitter, wherein the first emitter emits radiation at a different wavelength than the second emitter, and wherein the first emitter and the second emitter are used in a common curing step. This process step, in particular, can offer advantages over prior art solutions.

[0057] An embodiment in which the first emitter and the second emitter are to be used in a common curing step is understood, within the meaning of the present invention, to mean, in particular, that two emitters with different wavelengths are used during a curing process, i.e., when the corresponding layer, such as the cover layer, is partially cured and / or when the cover layer is finally cured. In other words, it can be provided that in one, several, or all curing processes, the cover layer is cured using two emitters with mutually different wavelengths.

[0058] According to the invention, this is achieved in that a curing step takes place using a radiation arrangement which has a first radiator and which has a second radiator, wherein the first radiator and the second radiator are designed to emit radiation with a different wavelength. The radiation arrangement is designed in particular to irradiate the cover layer by the first radiator and by the second radiator simultaneously, at least partially at the same position or at least partially at different, but adjacent positions. The cover layer is thus treated by the first radiator and the second radiator without further intermediate steps and thus in a common curing step by a common curing arrangement or radiation arrangement with two radiators.This differs significantly from the state of the art, where, for example, partial curing is first carried out with a first wavelength, followed by structuring and then final curing.

[0059] By curing the top layer using a first emitter and a second emitter, the first emitter emitting radiation at a different wavelength than the second emitter, and the first emitter and the second emitter being used in a common curing step, the curing behavior of the top layer can be significantly improved. Specifically, such a curing process with at least two different wavelengths in a common curing step can enable improved curing. This can potentially shorten the exposure time to the radiation, which can optimize process times.

[0060] Furthermore, improved curing can increase the stability of the top layer, minimizing damage during transport or use. This can also allow structures incorporated into the top layer to remain intact even under high stress, which can improve the visual appearance even after intensive use.

[0061] Furthermore, it was surprisingly discovered that the above-described process can enable improved adhesion of the top layer to the underlying decoration. This can also further improve the stability of the panel, which can lead to the aforementioned advantages.

[0062] In this context, radiation with different wavelengths can be understood in particular as a first radiation and a second radiation, each having radiation maxima at at least one different position. For example, patterns of radiation maxima can be present that differ completely or at least partially based on position, wavelength, and / or, if applicable, intensity.

[0063] It may be preferred that the first emitter emits radiation with radiation maxima in a wavelength range from greater than or equal to 395 nm to less than or equal to 445 nm. Alternatively or additionally, it may be provided that the second emitter emits radiation with radiation maxima in a wavelength range from greater than or equal to 200 nm to less than or equal to 440 nm. Furthermore, it may be provided that both emitters emit radiation with radiation maxima in a wavelength range from greater than or equal to 200 nm to less than or equal to 445 nm. It has surprisingly been found that, in particular, the use of one of the two aforementioned emitters, or particularly preferably a combination of the aforementioned emitters, can improve the advantages with regard to process control and the stability of the resulting product.

[0064] As a non-limiting example, the first emitter may be a gallium emitter and the second emitter a mercury emitter. In particular, a combination of a gallium emitter and a mercury emitter may allow the aforementioned wavelength ranges to be maintained, thus realizing the advantages in terms of process control and the stability of the resulting product.

[0065] It may further be preferred that the radiation intensity of the first radiator is in a ratio of greater than or equal to 0.5 / 1 to less than or equal to 1 / 0.5 to the radiation intensity of the second radiator. This enables a substantially uniform radiation intensity of the two radiators, which can further improve the curing result. It may preferably be provided that the radiation intensity of the first radiator is in a ratio of greater than or equal to 0.75 / 1 to less than or equal to 1 / 0.75 to the radiation intensity of the second radiator, for example in a ratio of greater than or equal to 0.9 / 1 to less than or equal to 1 / 0.9.

[0066] Furthermore, it may be preferred that the exposure time, for example at a travel speed of the carrier during hardening of 25-35 m / s, is within a period of approximately one second, so that, depending on a fundamentally variable radiation focus, an exposure time of the total radiation to a position of less than 1 second may be sufficient.

[0067] Furthermore, it may be preferred that the first radiator and the second radiator are aligned in such a way that the radiation of the first radiator and the radiation of the second radiator simultaneously fall at least partially on different positions of the cover layer, so that in a process along the radiators the cover layer is first treated by the first radiator and in particular immediately thereafter, i.e. without further intermediate steps, by the second radiator.In this case, it can be provided that the first radiator and the second radiator are aligned in such a way that the radiation of the first radiator and the radiation of the second radiator fall simultaneously and completely on different positions of the cover layer, or that the first radiator and the second radiator are aligned in such a way that the radiation of the first radiator and the radiation of the second radiator fall simultaneously partly on different positions of the cover layer and partly on an identical position of the cover layer, for example due to scattering of the radiation. In this embodiment, the cover layer can thus first be cured by radiation of one wavelength and, in particular, immediately afterwards by radiation of a further wavelength. It has surprisingly been shown that this embodiment can also allow advantages with regard to curing.In particular, treatment with different wavelengths can be more specific to the respective wavelength, which can make curing more adaptable to the respective application area, for example, to the specific composition of the top layer.

[0068] In particular, in this embodiment, it can be provided that the cover layer is first treated with radiation having radiation maxima in a wavelength range from greater than or equal to 395 nm to less than or equal to 445 nm and then with radiation having radiation maxima in a wavelength range from greater than or equal to 200 nm to less than or equal to 440 nm. For example, the cover layer can first be treated with a gallium radiator and then with a mercury radiator. It has surprisingly been found that, in particular, this embodiment allows for particularly preferential curing.

[0069] Furthermore, it can be advantageous for the first radiator and the second radiator to be aligned such that the radiation from the first radiator and the radiation from the second radiator simultaneously at least partially fall on an identical position on the cover layer. In this embodiment, it can thus be provided that the cover layer is treated at least partially simultaneously by the first radiator and the second radiator or by the corresponding radiation from the first radiator and the second radiator. For example, the radiation from the first radiator and the second radiator can fall entirely on the same area of ​​the cover layer at the same time. In this embodiment, curing can be possible particularly quickly, which can enable short process times and thus cost-effective production.

[0070] The invention is further explained below with reference to the figures and an embodiment. Fig. 1shows schematically an embodiment of a method for producing a decorated panel; Fig. 2 shows a detailed view of a radiation unit in a first embodiment; and Fig. 3 shows a detailed view of a radiation unit in a further embodiment.

[0071] In the Figure 1 a method for producing a decorated wall or floor panel 10 is shown schematically.

[0072] A conveyor device 100 is shown, on which an intermediate product comprising a carrier 12 is conveyed in the direction of arrow 110. The carrier 12 can be provided in a manner known per se and can generally be formed from a suitable material.

[0073] In this case, it is initially provided that a primer 16 is applied to the carrier 12 by an application device 14. The primer 16 can be UV-curable and cured by the blasting unit 18. Following the application of the primer 16, a two-layer adhesive white primer 24 can be applied by the application devices 20, 22. The adhesive white primer 24 can in turn be UV-curable and cured by the blasting unit 26, 28, in particular after the application of each layer.

[0074] The primer 16 or the adhesive white base 24 serves as the printing substrate. Thus, using a digital printing unit 30, the carrier 12 is printed, forming a decoration 32.

[0075] Subsequently, a further application unit 34 can apply a primer 36, in particular a UV-curable primer, and cure it by the blasting unit 38. The primer 36 serves as the base for a cover layer 40. The cover layer 40 can comprise a plurality of layers 40', 40", in particular comprising a radiation-curing lacquer, which can be applied by application devices 42, 44 and, after application, can be cured by blasting units 46, 48.

[0076] Furthermore, the cover layer 40 comprises a further layer 40‴, which has a structure, in particular in the sense of a synchronous pore. For this purpose, a further digital printing unit 50 is provided, which prints the layer 40‴ in the sense of positive structuring in order to create a defined structure. The layer 40‴ can then be cured directly by the blasting unit 52, or a final layer 56 can be applied by the application unit 54, followed by curing.

[0077] In the Figure 2 and 3 Each embodiment of the radiation unit 52 is shown, whereby the statements made here can generally apply to each of the described radiation units 16, 26, 28, 38, 46, 48. Particularly preferably, the embodiments shown can be used for the radiation units 18, 26, and 28 in addition to the radiation unit 52.

[0078] It can be seen that for hardening the cover layer 40, such as the layer 40‴ to be referred to as the structural layer, the radiation unit 52 has a first radiator 58 and a second radiator 60, wherein the first radiator 58 emits radiation with a different wavelength than the radiation of the second radiator 60. In particular, the first radiator 58 is a gallium radiator and the second radiator 60 is a mercury radiator. By providing the first radiator 58 and the second radiator 60, a particularly advantageous hardening can be realized. In particular, the respective radiation unit 16, 26, 28, 38, 46, 48, 52 can be provided to harden the corresponding layer to be hardened during a hardening process with different wavelengths.

[0079] According to Figure 2it is provided that the first radiator 58 and the second radiator 60 are aligned such that the radiation of the first radiator 58 and the radiation of the second radiator 60 simultaneously fall at least partially onto an identical position of the cover layer 40.

[0080] A preferred embodiment is in Figure 3 shown, according to which the first radiator 58 and the second radiator 60 are aligned such that the radiation of the first radiator 58 and the radiation of the second radiator 60 simultaneously fall at least partially on different but adjacent, i.e. in particular juxtaposed, positions of the cover layer 40. Reference symbol

[0081] 10Wall or floor panel 12Support 14Applicator 16Primer 18Blasting unit 20Applicator 22Applicator 24Adhesive white primer 26Blasting unit 28Blasting unit 30Digital printing unit 32Decor 34Applicator 36Adhesive primer 38Blasting unit 40Top coat 40'Layer of top coat 40"Layer of top coat 40‴Layer of top coat 42Applicator 44Applicator 46Blasting unit 48Blasting unit 50Digital printing unit 52Blasting unit 54Applicator 56Finishing coat 58Blasting unit 60Blasting unit 100Conveyor 110Arrow

Claims

1. Method for producing a decorated wall or floor panel (10), comprising the steps: a) providing a plate-shaped carrier (12); b) applying a decoration (32) replicating a decorative template onto at least a part of the plate-shaped carrier (12); c) applying a covering layer (40) onto the decoration (32), wherein the covering layer (40) comprises a radiation-curable compound; and d) curing the covering layer (40); wherein method step b) is carried out by a digital printing method and in that method step c) is carried out at least partially by a digital printing method and wherein, in order to form the covering layer (40), at least initially a first layer (40') is applied to the decor (32) and subsequently a structure-imposing layer (40‴) is applied by means of a digital printing device (50), to which a final layer (56) is applied by means of an application unit (54) and subsequently a hardening according to step d) is carried out, characterized in that in step d), the covering layer (40) is cured using a first radiator (58) and a second radiator (60), wherein the first radiator (58) emits radiation with a different wavelength compared to radiation from the second radiator (60) and wherein the first radiator (58) and the second radiator (60) are used in a common curing step without further intermediate steps.

2. Method according to claim 1, characterized in that the first radiator (58) emits radiation with radiation maxima in a wavelength range of greater than or equal to 395 nm to less than or equal to 445 nm.

3. Method according to claim 1 or 2, characterized in that the second radiator (60) emits radiation with radiation maxima in a wavelength range of greater than or equal to 200 nm to less than or equal to 440 nm.

4. Method according to any one of claims 2 or 3, characterized in that the first radiator (58) is a gallium radiator and the second radiator (60) is a mercury radiator.

5. Method according to any one of the preceding claims, characterized in that the ratio between the radiation intensity of the first radiator (58) and the radiation intensity of the second radiator (60) is greater than or equal to 0.5:1 to less than or equal to 1:0.5.

6. Method according to any one of the preceding claims, characterized in that the first radiator (58) and the second radiator (60) are aligned such that the radiation of the first radiator (58) and the radiation of the second radiator (60) impinge at the same time at least partially on different positions of the covering layer (40).

7. Method according to claim 6, characterized in that the covering layer (40) is treated in step d) first by a gallium radiator and then by a mercury radiator.

8. Method according to any one of the preceding claims, characterized in that the first radiator (58) and the second radiator (60) are aligned such that the radiation of the first radiator (58) and the radiation of the second radiator (60) impinge at the same time at least partially on an identical position of the covering layer (40).

9. Method according to any one of the preceding claims, characterized in that a radiation-curable lacquer is applied as the covering layer (40).

10. Method according to claim 9, characterized in that the radiation-curable lacquer is an acrylic lacquer.

11. Method according to one of the preceding claims, characterized in that the covering layer (40) is provided with abrasion-resistant particles.

12. Method according to any one of the preceding claims, characterized in that the carrier (12) comprises a matrix material and a solid material distributed in the matrix material, wherein the solid material is formed by talcum in an amount of least 50 wt.-%, based on the solid material, wherein the matrix material is present in an amount, based on the carrier material, from ≥ 30 wt.-% to ≤ 70 wt.-%, and wherein the solid material, based on the carrier material, is present in an amount from ≥ 30 wt.-% to ≤ 70 wt.-%, and wherein the carrier material and the solid material, based on the carrier material, are present together in an amount of ≥ 95 wt.-%.

13. Method according to claim 12, characterized in that the matrix material comprises polypropylene, wherein the polypropylene is a mixture of a homopolymer and a copolymer.