Method for providing laminate panels with individualised decorations

Abstract

The invention relates to a method for providing laminate panels, in particular wood laminate panels, provided with individualised decorations for a party B, in particular an end consumer, comprising the steps of: providing at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, the laminate panel blank comprising a carrier plate compressed with a coating as print primer and at least one counterpart and connection elements inserted into the panel edges; printing at least one decoration selected individually by the end consumer onto the laminate panel blank by means of digital printing; and pressing at least one thermoplastic film as wear layer onto the printed decoration. The decoration is printed on and the film pressed on at the point-of-sale (POS).

Description

[0001] The present invention relates to a method for providing laminate panels with individualized decors. Description

[0002] Laminate panels have become indispensable in a wide variety of applications, especially as a replacement for solid wood panels. A particularly large area of ​​application is the cladding of walls, ceilings, and floors, where the respective covering is assembled from corresponding wall, ceiling, and floor panels. Naturally, different applications place different demands on the surface finish of such laminate panels. A floor panel, by its very nature, is subjected to significantly greater stresses than, for example, a wall or ceiling covering.

[0003] The large-scale production of laminate panels encompasses a whole series of manufacturing steps, which are largely the same for the various applications of laminate panels. First, a core board, for example made of a wood-based material such as particleboard, MDF, HDF, or OSB, is prepared and coated with several layers of potentially different materials. A decorative layer is then applied to the surface of the wood-based panel, which may have been pre-treated. This can be done, for example, with printed, impregnated paper. The decorative layer can also be printed directly onto the top surface of the wood-based panel. This can be done using printing rollers or a digital printer. Before the decorative layer is printed, a primer may also be applied to the surface of the wood-based panel.This decorative layer, especially if the panel is intended for use as flooring, must be covered with at least one abrasion-resistant protective layer, such as lacquer or resin. The layered structure is then pressed together in a press under pressure and temperature. The still large-format, now coated, wood-based panel is then cut into individual panels, which are fitted with tongue-and-groove locking mechanisms on their sides to allow for easy connection.

[0004] A major theme in many product areas of wood-based panels today is customization. Customers often want a product tailored to their individual wishes and / or needs. They are also willing to pay a higher price for this additional service.

[0005] New technologies such as digital printing and 3D printing are opening up new possibilities for manufacturers, enabling them to produce small batches (e.g., single units) and utilize new production methods outside of traditional production lines. Many products are affected by these trends, including flooring. Traditionally, flooring was produced in large quantities per design at the manufacturers' plants. These designs were usually developed by suppliers (designers, printers, etc.) and then distributed to the industry. From a specific number of designs, flooring manufacturers would then create a collection and make it available to flooring retailers and, ultimately, to end customers.

[0006] Previously, this approach offered little to no scope for individualization. Customer involvement was also impossible. This applied essentially to all floor coverings, including laminate flooring.

[0007] In recent years, there have been increasing efforts to satisfy the demand for customized flooring. However, the process has often been somewhat complicated, as the end customer had to order their desired customized flooring from the manufacturer through a retailer. This not only led to sometimes very long delivery times but also to potential problems if the actual flooring delivered differed significantly from a sample or a digital image. The range of possible designs is also usually limited to prevent the manufacturer from having to process too much variety. Another problem is that very small order quantities often have to be shipped, resulting in relatively high transport costs per square meter of product.

[0008] To address this problem, a process according to EP 2 572 896 B1 was used, in which coated plank blanks are printed with a decorative design at the point of sale (POS) and then varnished. However, this process has the disadvantage that the varnishes used are UV-curing systems (acrylates) which, due to the required photoinitiators, can cause unpleasant odors. This must be prevented by exhaust air disposal. Furthermore, the acrylates are allergenic, which necessitates special training and appropriate protective equipment for POS staff during maintenance, cleaning, or troubleshooting. Disposing of defective batches / rejects is also problematic for employees. In addition, quality control is difficult for those unfamiliar with UV varnish technology.The use of UV lacquers is more suitable for industrial companies and less so for employees in DIY stores, timber merchants, flooring retailers, etc. Furthermore, varying the surface texture is hardly possible, so only one surface finish is available.

[0009] A similar process is described in EP 3 067 219 A1. It suffers from the same disadvantages as the aforementioned document. Additionally, EP 3 067 219 A1 describes the application of a synthetic resin coating as a wear layer using pressure and temperature. For reasons similar to those of painting (high technical complexity, high level of technical expertise, disposal issues, etc.), this is considered impractical. Furthermore, the synthetic resin coating process takes place at relatively high temperatures (approx. 200°C), resulting in a significant energy demand for such a system.

[0010] The resulting disadvantages are odor nuisance, no surface variations, sophisticated technology requiring employees with a high level of technical understanding, and exhaust air and disposal problems.

[0011] The present invention therefore addresses the technical problem of providing a method that enables end customers to purchase a custom-designed floor at the point of sale (POS), such as a building supply store, and take it home immediately. This allows customers to work with either their own designs or existing (digital) decors. For employees at the point of sale, the operation and maintenance of the flooring production system should be as simple and safe as possible. No emissions or odors should occur. Furthermore, troubleshooting, maintenance, and reloading of the system should be as straightforward as possible.

[0012] This technical problem is solved by a method having the features of claim 1.

[0013] Accordingly, a method for providing laminate panels, in particular wood-based laminate panels, with customized decors to a party B, in particular an end consumer, is provided, which comprises the following steps: Provision of at least one formatted laminate panel blank by Party A, in particular a laminate manufacturer, wherein the laminate panel blank comprises a carrier board pressed with a coating as a printing primer and at least one backing layer, and connecting elements inserted into the panel edges; digital printing of at least one decor individually selected by the end user onto the laminate panel blank; pressing of at least one thermoplastic film coated with at least one layer of lacquer as a wear layer onto the printed decor, wherein the at least one layer of lacquer is applied to the thermoplastic film in an amount between 30 and 100 g / m², preferably between 60 and 80 g / m². where the printing of the selected decor and the pressing of at least one thermoplastic film onto the printed decor takes place at the point of sale (POS).

[0014] Party A shall be understood to mean in particular a laminate manufacturer, also suppliers, dealers or similar, who provides Party B with laminate panel blanks for individualization in the manner of an intermediate product.

[0015] Party B is understood to refer in particular to an end consumer, including interior decorators or architects, who use or offer laminate panels as a finished end product for covering floors, walls and / or ceilings.

[0016] Accordingly, a process is provided whereby a non-customized laminate panel blank is initially supplied by the manufacturer. As described in detail below, the manufacturer presses a large-format core board with a primer layer, optionally a primer, and a backing layer, the primer layer having a uniform, preferably light, color. The primer layer may be textured. The pressed, large-format board is divided into individual panels and fitted with known locking elements along the side edges. The manufacturer thus provides (small-format) laminate panel blanks with a high degree of processing (i.e., with pressure primer and connecting elements) that can subsequently be customized by the end user.

[0017] The manufacturer delivers the small-format laminate panel blank to a point of sale (e.g., a DIY store). There, according to the present process, a decor individually designed by the end consumer is digitally printed onto the panel, and this printed decor is then coated with a wear-resistant film. This eliminates the need for liquid lacquer or resin layers as a wear layer, making the finishing process simpler and safer. In particular, emissions and unpleasant odors for employees at the point of sale are avoided. The end consumer also has the option of integrating their own decors or inlays into the flooring. Complex, multi-layered laminate structures are not provided at the point of sale using this process, as this would increase the product's price, which is precisely what is not desired.Therefore, no load distribution layer, stabilization layer or damping layers made of, for example, cork, felt, fleeces, wood-plastic composite (WPC), glass fiber reinforced plastic, hot melts or similar materials are used in this case.

[0018] The system used for this point-of-sale process includes a magazine containing laminate panel blanks (coated, primed, and tongue-and-groove). These blanks are printed with a digital printer, either with designs provided by the system supplier or with designs uploaded by the end user via a digital file (e.g., stored on a USB drive). It is also possible to integrate inlays, names, etc., into a design provided by the system supplier. Further editing of the design files is possible using simple software (rotating, mirroring, enlarging, reducing, etc.). The results of these adjustments can be viewed not only on a screen but also on a printout.A foil, which may have a layer of varnish on the top side, is then applied to the printed decoration using a heated roller.

[0019] Delivering the laminate flooring blanks directly to the point of sale (POS) solves the problem of supplying end customers with small quantities, a problem that arose due to customization. This allows even minimal quantities (e.g., batch size 1) to be individually designed for the end consumer. This would not be possible for the laminate manufacturer itself. The ability for the end customer to customize a product represents the maximum possible level of consumer involvement in the product manufacturing process.

[0020] Furthermore, only a digital printer and a roll of lamination in the width of the planks are required for surface finishing. If necessary, films for different usage classes can also be used, as this only requires changing a roll.

[0021] The advantages of the present method are manifold: the end product is ready immediately, modifications to the decor can be made, surfaces can be varied, it is a simple process that can be carried out in a flexible system, and customer-specific quantities can be provided.

[0022] As described, the laminate panel blank, with the pressure primer, backing layer and locking elements, is provided by the laminate manufacturer.

[0023] The laminate panel blank comprises a wood-based panel as its core or carrier board, which can be a medium-density fiberboard (MDF), high-density fiberboard (HDF), particleboard, oriented strand board (OSB), plywood, and / or a wood-plastic composite board.

[0024] In one embodiment, an unsanded wood fiberboard, in particular MDF or HDF, is used as a carrier board for the laminate panel blank, which is still provided with a pressed skin (rot layer) on the top side and has been coated with an aqueous melamine resin on the top side to fill the pressed skin.

[0025] The dimensions of the laminate panel blank correspond to the formats typically available in stores (e.g., DIY stores). For example, the laminate panel blank can have dimensions of 1395 x 195 mm with a thickness between 4 and 15 mm, preferably 6 to 12 mm (small format). Other formats are also possible.

[0026] As explained above, at least one laminate panel blank has a coating that acts as a printing primer. This primer is applied to large-format substrate panels by the manufacturer. To ensure particularly good printability of the laminate panel blanks produced in this way, the primer is specifically colored. Several colors are possible, such as white, beige, yellow, or brown.

[0027] In one embodiment, the at least one printing primer consists of a liquid coating of a resin, preferably a formaldehyde resin, such as melamine-formaldehyde resin, urea-formaldehyde resin, or melamine-urea-formaldehyde resin. After intermediate drying, a pigmented layer is applied to this primer, for example, with a binder base of casein or soy protein. White pigments such as titanium dioxide (TiO₂) can be used as color pigments. Other color pigments can be calcium carbonate, barium sulfate, or barium carbonate. The liquid primers can be applied to the surface of the substrate using a roller.

[0028] It is also conceivable that the primers consist of at least one, preferably at least two or more successively applied layers or coatings, wherein the coating quantity between the layers or coatings is the same or different, i.e. the coating quantity of each individual layer can vary.

[0029] In another embodiment, the at least one printing primer consists of colored paper impregnated with a resin. For example, colored papers are used as the printing base, the color of which corresponds to the lightest shade in the design to be printed. If, as in the present case, the design to be applied is not yet known, a white or at least very light primer is therefore advantageous. However, any other color is equally conceivable as a primer.

[0030] In another embodiment, the large-format panel, coated with at least one primer layer, is pressed with a counter-pressure. This is typically done in a short-cycle press at the panel manufacturer. A structure can be introduced into the primer layer during the pressing process.

[0031] It is also possible to apply at least one primer layer to the initial printing primer (applied by the panel manufacturer). Isocyanate-based compounds can be used as primers, with non-aromatic, aliphatic isocyanates, such as hexamethylene diisocyanate, isophorone diisocyanate, or prepolymers containing these isocyanates, being particularly preferred. Silane-based primers can also be used, such as products from Inomat GmbH. These contain acidolysis products of silanes, for example, bis(3-trimethoxysilylpropyl)amine and p-toluenesulfonic acid.

[0032] The amount of liquid primer applied is between 1 and 30 g / m², preferably between 5 and 20 g / m², and particularly preferably between 10 and 15 g / m².

[0033] To protect the printed design and primer from dirt and to prevent the laminate flooring blanks from sticking together during transport and storage at the point of sale, a release film can be used. Films with a silicone coating can be used as release films.

[0034] The described steps of priming and, if necessary, applying a primer layer and pressing are carried out in large format at the manufacturer's facility. The primed large format is then also divided or formatted into the desired number of laminate panel blanks at the manufacturer's facility.

[0035] The now-formatted laminate panel blanks are fitted with a lockable tongue-and-groove connection at the manufacturer on at least two opposing edges of the panel. This allows for easy and quick floating installation of the panels. Such tongue-and-groove connections are known, among other places, from EP 1 084 317 B1.

[0036] The laminate panel blank provided by the manufacturer therefore comprises a wood-based panel as a carrier board with at least one printed primer, possibly a primer layer provided on the printed primer, a counter-layer opposite the printed primer and lockable tongue-and-groove connections provided on at least two opposing edges of the panel.

[0037] The laminate panel blanks are stored in a central warehouse at the laminate manufacturer. They can be cleaned and packaged beforehand so that they can be printed or processed directly at the downstream processing plant without requiring further cleaning. Now, only one type of panel needs to be kept in stock, eliminating the need for space-intensive storage of panels with different decors, surface textures, or finishes.

[0038] The laminate panel blanks are then transported to a processing facility for customization. This could be, for example, a franchise affiliated with the laminate manufacturer, a DIY store, an interior designer, a retailer, or a flooring installer.

[0039] In this process, the laminate panel blanks are unpacked from their transport-safe packaging. Then, as described above, a decorative layer with a design according to the customer's specific requirements is applied to the primer and covered by at least one wear layer.

[0040] As mentioned above, at least one decorative design (individually selected by the end user) is applied to the laminate panel blank using a digital printing process. In digital printing, the print image is transferred directly from a computer to a printing machine, such as a laser or inkjet printer. This eliminates the need for a static printing plate. The decorative printing process follows the inkjet principle in a single pass, where the entire width of the surface to be printed is covered as the panels move under the printer. However, it is also possible for the panel to be paused under the printer, which then passes over the surface at least once during printing.

[0041] Digital printing allows for a selection of decors tailored to customer requirements, as the decor can be provided in the form of customized computer data / software. The laminate panel blanks are printed with a digital printer, either with decors provided by the equipment supplier or with decors uploaded by the end user via a file. It is also possible to integrate inlays, names, etc., into a decor specified by the equipment supplier. Further editing of the decor files is also possible using user-friendly software (rotating, mirroring, enlarging, reducing, etc.). Moreover, the results of these adjustments can be viewed not only on a screen but also on a printout.

[0042] In the printing step, the laminate panel blank passes through a digital printer. This makes it possible to quickly and easily print different decors onto different panels one after the other, without having to reconfigure the printing unit for each new decor. Because only individual panels need to be printed, and not entire large-format wood-based panels as is usual with current technology, the printing unit can be small and compact, thus saving space and costs.

[0043] The printing inks are grouped in separate printhead rows in the digital printer, with one or two rows of printheads available for each color. Examples of digital printing ink colors include black, blue, red, reddish yellow, and greenish yellow; CMYK is also optional. Digital printing inks are optionally based on the same pigments used for analog and / or digital printing with water-based inks. UV-cured digital printing inks are preferred, but water-based or hybrid inks are also possible. After printing, the decorative print undergoes drying and / or irradiation.

[0044] The printing inks are applied in an amount between 1 and 30 g / m², preferably between 3 and 20 g / m², and particularly preferably between 3 and 10 g / m².

[0045] As mentioned above, a thermoplastic film is applied to the printed design as a wear layer. In one embodiment, a transparent cover film made of a thermoplastic material, in particular thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), or polypropylene (PP), is used. The TPUs are aliphatic systems because they are less susceptible to yellowing.

[0046] The films used have a thickness between 0.1 and 1 mm, preferably between 0.2 and 0.8 mm. They can be single- or multi-layered and contain mineral components (e.g., corundum particles) to improve wear resistance.

[0047] The transparent thermoplastic film is manufactured separately and fed online from a roll. The at least one thermoplastic film is applied to the printed laminate panel blank at a temperature up to 20°C above the softening temperature of the film's thermoplastic material. Heating the film above its softening point ensures good adhesion to the printed layer.

[0048] The film is pressed on with a line pressure between 100 and 170 N / mm, preferably at 150 N / mm (this assumes an idealized line in a laminating machine).

[0049] The film is, in particular, laminated or calendered. Calendering is preferably carried out using a heated structuring roller. For the purposes of this application, "calendering" is understood to mean the application of a thermoplastic film to a substrate using heated rollers. This results in the surface of the thermoplastic film melting, and after hardening, the film is bonded or welded to the substrate and thus adheres to it. Accordingly, no adhesive is necessary.

[0050] According to the invention, the at least one thermoplastic film is provided or coated with at least one lacquer layer. In this case, the thermoplastic film is supplied together with the lacquer layer; i.e., the lacquer layer is already present on the film in a cured form, so that application and curing of the lacquer layer at the point of sale is not necessary. The at least one lacquer layer serves to improve scratch resistance and adjust the gloss level. The lacquer layer can contain nanoparticles, e.g., made of silica.

[0051] The coating layer can consist of at least one polyurethane or of radiation-curable acrylate-containing coatings. Typically, the radiation-curable coatings used contain (meth)acrylates, such as polyester (meth)acrylate, polyether (meth)acrylate, epoxy (meth)acrylate, or urethane (meth)acrylate. It is also conceivable that the acrylate used, or the acrylate-containing coating, consists of substituted or unsubstituted monomers, oligomers, and / or polymers, particularly in the form of acrylic acid, acrylate ether, and / or acrylic acid ester monomers, oligomers, or polymers. Of importance for the present process is the presence, by definition, of a double bond or unsaturated group in the acrylate molecule. The polyacrylates can also be functionalized. Suitable functional groups include hydroxy, amino, epoxy, and / or carboxyl groups. The aforementioned acrylates enable crosslinking or curing in the presence of UV or other radiation.Electron beams (ESH).

[0052] The coating is applied to the thermoplastic film in an amount between 30 and 100 g / m², preferably between 60 and 80 g / m².

[0053] It is also possible to texture the at least one thermoplastic film and the coating layer applied to it. For this purpose, the heated roller used to press the thermoplastic film onto the film can also have a textured surface. A quick-change system allows for automatic roller changes, enabling variations in the texture.

[0054] It is also possible for the structure to run parallel to the decor within the register, a so-called EIR structure or decor-synchronous structure. For this, the position and speed between the substrate to be structured and the structure generator (roller) are synchronized. Using the present method, a laminate panel, in particular a wood-based laminate panel, can be produced which has a layer structure consisting of at least one backing layer, a substrate, at least one decor base layer, optionally at least one primer layer, at least one (customized) printed decor layer, at least one thermoplastic film, and optionally at least one lacquer layer.

[0055] A suitable device for providing this laminate panel includes at least one digital printer for printing at least one decor onto a laminate panel blank, which comprises a carrier board pressed with a coating as a printing primer and at least one counter-pressure and connecting elements inserted into the panel edges, using digital printing; and at least one roller device for pressing at least one thermoplastic film as a wear layer onto the printed decor.

[0056] The device also includes at least one magazine containing laminate panel blanks (coated, primed and tongue and groove).

[0057] A cleaning device may also be installed upstream of the printing unit or digital printer.

[0058] The at least one digital printer is connected to at least one electronic data processing device. The data processing device of the digital printer comprises an input device with which a selection of a design can be entered, which is stored as electronic data in a data memory, and an electrical control unit which is configured to read the selected design from the data memory and to control the printing unit so that the selected design is printed.

[0059] The device also includes a display unit that shows the available decors or decors provided by the end user.

[0060] It is also possible that the at least one roller assembly includes at least one roller with a structured surface. Roller changes can be performed automatically via a changeover system, allowing for variations in the structure.

[0061] A significant advantage of the device described above is that the at least one digital printer and the at least one roller device are adapted to the dimensions of the laminate panel blank, i.e., the digital printer and roller device are adapted to the plank width and are therefore more space-saving and cost-effective.

[0062] Specifically, this procedure can be implemented in one variant, for example, in a home improvement store, as follows. A customer who needs laminate panels for a specific room size first receives information about the number of panels required. On a display unit of a device used to finish the laminate panel blank as described above, they can view various available decors. These decors are stored as electronic data in a data memory within the device. Alternatively, the customer or end user can bring their own decor on a suitable data carrier (e.g., a CD, DVD, or USB stick). This allows the customer to have a custom decor printed onto the panels. After selecting a decor, the customer enters this selection via the input device.Furthermore, the customer can choose how many laminate panel blanks should be printed with the selected decor. Within the machine, the desired decor is applied to a pre-primed, profiled panel and then covered with a thermoplastic film as a wear layer. End users can reorder individual panels at any time using the same machine. This significantly increases flexibility in the production of laminate panels, making even the smallest order quantities with a wide variety of decors economically viable.

[0063] The present invention is explained in more detail below with reference to a figure and an exemplary embodiment. It shows: Figure 1 is a schematic representation of an embodiment of the present method.

[0064] Figure 1Figure 1 shows a schematic representation of a process for refining a laminate panel blank, as it can be carried out in a processing plant, for example a franchisee associated with the laminate manufacturer, a hardware store or similar.

[0065] The laminate panel blanks 101 are delivered to the processing plant from the laminate manufacturer in transport-safe packaging. In the first process step, the laminate panel blanks 101 are removed from this transport-safe packaging and fed into a magazine.

[0066] In the Figure 1In the illustrated embodiment of the method, the laminate panel blanks 101 are subsequently fed to a cleaning device 102, in which the surface of the laminate panel blanks 101 is cleaned of any adhering dirt residues and dust, thus preparing them for printing. However, it is also conceivable that the laminate panel blanks 101 were cleaned to a suitable standard for subsequent printing at the laminate manufacturer's facility. These could then have been placed in the transport-safe packaging after cleaning. For example, by hermetically sealing the transport packaging in a film, it can be ensured that the laminate panel blanks 101 do not need to be cleaned again before printing.

[0067] After the laminate panel blanks 101 have passed through the cleaning device 102, if necessary, they are aligned and spaced apart at the desired distance. The laminate panel blanks 101 are then fed to a digital printer 103. Here, the surface of the panel 101 is printed with the decorative layer to be applied. For this purpose, the digital printer 103 has three printheads. Depending on the desired decor, the digital printer 103 may also have more or fewer printheads. An electronic data processing unit 104 is connected to the digital printer 103. This unit has a Figure 1The input device (not shown) allows the user of a device for carrying out the procedure to select the desired decoration. The electronic data processing device 104 has a display unit that shows the available decorations, which are stored, for example, on an electronic storage medium, to the user. From this selection, the user can choose the desired print decoration.

[0068] To ensure the best possible result, the decors are optimized and adapted in the data processing unit 104 to the possible formats of the laminate panel blanks 101 to be printed.

[0069] After the top surface of the laminate panel blanks 101 has been printed with a design, the printed panels 101 leave the digital printer 103 and are fed to a roller device 105, in which a transparent thermoplastic wear film is pressed onto them. The film is cut to size after the pressing process. If necessary, cooling (roller cooling) can also be integrated into the process. After the wear film is pressed onto the printed panel, the end user has a laminate panel tailored to their individual requirements, which can be used, for example, as a flooring element or for wall or furniture cladding. Example of implementation Provision of the laminate panel blanks at the laminate manufacturer:

[0070] The large-format wood-based panels are primed. The primer can either be a colored paper base or a liquid coating followed by a melamine resin coating. The liquid coating can be applied by roller or digital printing.

[0071] In the case of impregnation, colored paper undergoes a special impregnation process. First, the paper is filled with resin, then the top surface is sharply scraped with a knife-like squeegee, and finally the underside is coated with a layer of resin intended to improve adhesion to the substrate.

[0072] The priming is usually done on a large format (format 2800 mm x 2070 mm with a thickness of 4 to 15 mm, preferably 6 to 12 mm).

[0073] In every case, subsequent pressing in a short-cycle press with a counter-pull was carried out.

[0074] The laminate flooring blanks are then produced from this large format on a milling line.

[0075] A primer can be applied before or after formatting to further improve the adhesion of the subsequently applied film. This primer is applied at a rate of 10 to 20 g / m². It can be an isocyanate-based or silane-based primer (INOFLEX NI+). A release film can be used to protect the primer from contamination and to prevent the laminate flooring blanks from sticking together during transport and storage.

[0076] Locking profiles (connectors and locking elements) are usually milled into the side edges of the formatted panel blanks, possibly with plastic locking elements, then packaged, possibly temporarily stored and sent to the point of sale.

[0077] The laminate manufacturer essentially produces a "finished" laminate in white and stores it in stock. Finishing at the point of sale (e.g., hardware store):

[0078] The laminate panel blanks are unpacked and cleaned and inserted into the system consisting of a digital printer and roller device.

[0079] The system includes a magazine containing laminate panel blanks (coated, primed and tongue and groove).

[0080] At the point of sale, the laminate flooring blanks are printed with a digital printer, either with decors provided by the machine supplier or with decors uploaded by the end customer via a file. It is also possible to integrate inlays, names, etc., into a decor specified by the machine supplier. Further editing of the decor files is also possible using user-friendly software (rotating, mirroring, enlarging, reducing, etc.). The results of these adjustments can be viewed not only on a screen but also on a printout.

[0081] A TPU film, coated with a UV varnish layer on the top side, is then laminated onto the printed surface using a heated roller at a pressure of 150 N / mm and a temperature of 140°C. The film is fed from a roll and cut to size after lamination. The blanks are transported through the laminating press by a guide system equipped with special features to prevent damage to the profiled areas during the lamination process.

[0082] The heated roller that presses the film onto the print has a textured surface, allowing for subsequent texturing of the painted surface. A quick-change system enables automatic roller changes, allowing for variations in texture. The temperature used to apply the film is up to approximately 20°C above the softening temperature of the thermoplastic from which the film is made.

[0083] Delivering the laminate flooring blanks directly to the point of sale (POS) solves the problem of supplying end customers with small quantities, a problem that arose due to customization. Furthermore, only a digital printer and a roll of lamination in the width of the planks are required for surface finishing. If needed, films for different usage classes can also be used, as this only requires changing a single roll.

Claims

1. Method for providing laminate panels, in particular wood-based laminate panels, provided with individualized decors, for a party B, in particular an end user, comprising the steps: - Providing at least one formatted laminate panel blank by a party A, in particular a laminate manufacturer, wherein the laminate panel blank comprises a carrier board pressed with a coating as a print base coat and at least one backing and connecting elements inserted into the panel edges, - Printing at least one decor individually selected by party B, in particular the end user, on the laminate panel blank by digital printing; - Pressing at least one thermoplastic film coated with at least one lacquer layer onto the printed decoration as a wear layer, the at least one lacquer layer being applied to the thermoplastic film in an amount of between 30 and 100 g / m2, preferably between 60 and 80 g / m2; and - wherein the printing of the selected decoration and the pressing of the at least one thermoplastic film onto the printed decoration takes place at the point of sale (POS).

2. Method according to claim 1, characterized in that the at least one lacquer layer consists of at least one polyurethane or of radiation-curable acrylate-containing lacquers.

3. Method according to claim 2, characterized in that the radiation-curable lacquers used contain (meth)acrylates, in particular polyester (meth)acrylates, polyether (meth)acrylates, epoxy (meth)acrylates or urethane (meth)acrylates.

4. Method according to one of the preceding claims, characterized in that the at least one print base coat of the laminate panel blank is provided with a structure.

5. Method according to one of the preceding claims, characterized in that at least one primer layer is provided on the at least one print base coat of the laminate panel blank.

6. Method according to claim 5, characterized in that the liquid primer is applied to the at least one print base coat in a quantity of between 1 and 30 g / m2, preferably between 5 and 20 g / m2, in particular preferably between 10 and 15 g / m2.

7. Method according to claim 5 or 6, characterized in that isocyanate-based compounds, in particular non-aromatic, aliphatic isocyanates, such as hexamethylene diisocyanate, isophorone diisocyanate, or prepolymers containing these isocyanates, are used as primers.

8. Method according to one of the preceding claims, characterized in that the at least one decorative print is provided in the form of individualized computer data / software.

9. Method according to one of the preceding claims, characterized in that the printing inks are applied in an amount of between 1 and 30 g / m2, preferably between 3 and 20 g / m2, in particular preferably between 3 and 10 g / m2.

10. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film provided as a wear layer is a transparent cover film made of a thermoplastic material, in particular of thermoplastic polyurethane (TPU), polyethylene terephthalate (PET) or polypropylene (PP).

11. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film has a thickness of between 0.1 and 1 mm, preferably between 0.2 and 0.8 mm.

12. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film is applied to the printed panel blank at a temperature which is up to 20°C above the softening temperature of the thermoplastic material of the film.

13. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film is pressed on at a line pressure of between 100 and 170 N / mm, preferably at 150 N / mm.

14. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film is calendered using a heated roller.

15. Method according to one of the preceding claims, characterized in that the at least one thermoplastic film and the coating layer provided thereon are provided with a structuring.

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