Three-dimensionally structured decorative element

Abstract

The invention relates to a method for producing a three-dimensionally structured decorative element (10). The surface (26) of the support layer (22) is subjected to a 3D structuring process, and the decoration (52) is then applied thereon. A readable reference geometry (34) is produced on the surface (26), said geometry providing information on the position (36; 37; 50) of the structure (26). The reference geometry (34) is then read and used in order to control a downstream coating process (56) such that the decoration (52) is applied onto the produced 3D structure of the surface (26) of the support layer (22) in an intended manner. The invention additionally relates to a three-dimensionally structured decorative element (10) produced in such a manner and to a corresponding production system (12) with a controller (20).

Description

[0001] Three-dimensional structured decorative element

[0002] The present invention relates to a method for producing a three-dimensionally structured decorative element and to a three-dimensionally structured decorative element. Furthermore, the invention relates to a production system for producing a three-dimensionally structured decorative element and a corresponding control device.

[0003] Three-dimensionally structured decorative elements are used in many areas and can be produced in a variety of ways.

[0004] For example, EP 2 373 494 B1 discloses a method for producing coated panels in which a plastic layer is first applied to a substrate and then a relief is applied to a surface of the plastic layer.

[0005] EP 3 381 710 A1 describes another method for producing coated panels. An outer layer with a relief is produced by creating a pattern of cutouts using a material-repellent agent. EP 3 640 041 A1 describes a method in which similar cutouts are produced by a printing process.

[0006] CN 105835589B further describes a method for producing a coated sheet material with a relief. Production occurs by locally increasing or decreasing the volume of a surface layer.

[0007] WO 2021 / 116447 A1 further discloses a method for producing a structured wear-protection film. A lacquer-containing top layer is structured using a digital printing process.

[0008] EP 2 313 281 B1 further describes a method for producing a decoratively printed surface. A liquid base layer is applied, dried, and then coated by digital inkjet printing. EP 3 932 684 A1 further discloses a method for producing a relief on a substrate. Here, the relief is produced by sublimation.

[0009] EP 3 875 248 A1 describes another method for producing a three-dimensional structure on a surface. A relief is applied to the surface and covered with a covering.

[0010] Three-dimensionally textured decorative elements are increasingly finding their way into flooring. Here, a decorative coating that replicates a natural surface is often desired. One example of this is wood decor, where, for example, a natural grain or knot pattern is reproduced three-dimensionally and attractively colored.

[0011] Such decorations pose major challenges for manufacturing technology, particularly in the field of digital printing, where the decoration is printed from a digital data set directly onto a carrier layer.

[0012] Conventionally, a decorative substrate, such as film, paper, or similar, is often printed with a design and then coated onto a carrier layer. The carrier layer, initially coated with a 2D design, is then mechanically deformed or structured three-dimensionally to create a relief. Finally, the resulting 3D decorative element is often surface-coated for sealing, e.g., to protect a floor covering against wear.

[0013] Structuring is typically performed using a forming tool, such as a press plate or a press roller. The 3D structure of the 3D decoration to be produced is mapped into the forming tool. The 3D structure is then pressed or embossed into the carrier layer coated with the 2D decoration under high pressure and high temperature. To ensure that such 3D structuring or embossing can be aligned to match the 2D decoration, the forming tool has, for example, a so-called register mark. The pre-printed 2D decoration then also has such a register mark. For correct structuring, the register marks of the forming tool and the 2D decoration must then be aligned so that the 3D structuring is embossed onto the 2D decoration as intended. Conventionally, the alignment of the forming tool and the decoration can be achieved manually, for example by placing them together, or electronically, for example by optoelectronic registration.

[0014] US 2021 / 0245544 A1, for example, describes a method for producing a relief by printing and forming. A substrate is digitally printed, and then a three-dimensional structure is created using a rolling device.

[0015] Conventional production, comprising the application of decoratively printed printing films and subsequent structuring, often takes place in synchronized production processes, e.g. using a press plate with 3D structuring, or in continuous flow processes, e.g. using a press roller with 3D structuring.

[0016] In such flow processes, the production speeds of the decoratively coated substrate and the downstream structuring process must be adjusted or synchronized accordingly. This often leads to problems, as unpredictable effects such as jamming, slippage, and transverse and longitudinal contraction of the material can occur during the structuring process. Such effects occur particularly frequently with higher-density materials and affect the production speed of the structuring process, which can therefore fluctuate irregularly. Such fluctuations negatively impact the decorative appearance.

[0017] A further problem is that pressure is exerted on the surface with the decoration, which determines the aesthetic impression, during the structuring process, and heat may also be introduced. In the case of paper or foil as a decorative substrate, for example, this often leads to material warping. Color changes can also occur as a result of heat and pressure. Therefore, there are also conventional alternative processes based on the temporary addition of material to a carrier layer. For example, a layer of lacquer can be applied to the carrier layer, which is then selectively removed for structuring.

[0018] However, such processes, which require chemical or mechanical removal of the additional material, are complex and, moreover, environmentally questionable. To create an aesthetically pleasing decorative pattern with sufficient texture depth, a relatively large amount of textured paint must be applied, much of which must then be removed chemically or mechanically.

[0019] Finally, EP 3 640 042 A1 discloses a method in which a relief is produced using a mask.

[0020] However, such techniques are very complex due to the additional masking and unmasking process.

[0021] The present invention is therefore based on the object of proposing a method for producing a three-dimensionally structured decorative element that is low-cost and easy to control. Furthermore, the decorative element should achieve high quality and its production should be environmentally friendly.

[0022] The object is achieved by the subject matter of independent patent claims 1, 9, 11 and 12. Preferred embodiments of the present invention emerge from the features mentioned in the subclaims and further from the present disclosure as a whole.

[0023] A first aspect of the invention relates to a method for producing a three-dimensionally structured decorative element, comprising the following steps: -providing a carrier element;

[0024] Producing a three-dimensionally structured surface on the carrier element using a structuring device; - Producing at least one reference mark on the carrier element using a marking device, wherein the produced reference mark has a predetermined geometric relationship with the produced three-dimensionally structured surface, at least with regard to its position on the carrier element; and thereafter

[0025] - applying a decoration to the three-dimensionally structured surface with a coating device, wherein at least one relative position of the three-dimensionally structured surface to the coating device is determined on the basis of the reference mark and used to apply the decoration in a predetermined geometric relationship to the three-dimensionally structured surface.

[0026] In other words, a 3D pattern is first created on the surface of the carrier layer, and then the decoration is applied to it. A readable reference geometry is created on the surface, which provides information about the position of the pattern. The reference geometry is then read and used to control a downstream coating process so that the decoration is applied as intended to the created 3D pattern on the surface of the carrier layer.

[0027] The three-dimensionally structured decorative element produced using the method of the invention can preferably be a three-dimensionally structured floor covering element. However, other types of decorative elements can also be produced in principle. The carrier element can then comprise, for example, a floor covering blank, which can be made of wood, wood-based materials, polymers and combinations of these materials, such as PVC. For example, the aim can be for the three-dimensionally structured decorative element to be produced to replicate a natural wooden surface with a grain that is three-dimensionally structured in a specific way. For example, prominent cracks or even knots in the wooden surface can be replicated here, the natural appearance of which results from a combination of the three-dimensional structuring and the coloring.Then, for example, the structuring, comprising the cracks, the knots, and the reference mark, is first introduced into the surface of the carrier element, for example, by embossing. The decoration is then applied to the structuring. For the natural appearance, it is important that each crack or knot has a characteristic color, for example, a gradient or shaded color. Accordingly, specific color areas of the decoration must be applied to specific areas of the structuring. For this purpose, the reference mark, which has a defined relative position to, for example, the crack and the knot, is read out in order to apply the appropriate color areas to the crack and the knot.

[0028] The method of the invention thus allows the necessary components of "3D structuring" and "coloring" of the three-dimensionally structured decoration to be combined precisely and with minimal effort. Since the relative position of the 3D structuring and the coating device is known at all times via the recognition of the reference mark, the method is highly process-reliable, highly controllable, and particularly robust against random influences that could alter the relative position.

[0029] Due to the high process reliability, hardly any waste is produced. Furthermore, only temporarily applied additives are not required. The process of the invention is therefore also particularly ecological and economical.

[0030] Any material that can be structured three-dimensionally is suitable for the support element. Materials such as wood, plastics such as vinyl materials (PVC, LVT), or laminates, including such materials, are particularly preferred. Materials such as ceramic or stone are also possible.

[0031] The surface can be structured three-dimensionally, for example, with a relief, a texture, or the like. Depending on the material, various structuring methods can be used, and an appropriately designed structuring device can be employed. Structural methods for deformable materials, such as wood or plastic, are preferably formed, such as embossing or pressing. This can also be supported by the use of heat. For hard materials, such as ceramics or stone, separation methods such as milling, water or sandblasting, or even laser processing are preferred.

[0032] In the context of the invention, the reference mark can also be referred to as a register mark. It can be produced before the structuring process, simultaneously with it, or downstream. Accordingly, the marking device can be integrated with the structuring device or provided downstream. The register mark is preferably produced simultaneously with the structuring process, as this makes the process particularly efficient and, at the same time, allows a very precise, intended geometric relationship between the reference mark and the three-dimensionally structured surface to be achieved. It is advantageous to coordinate data transmitted to the structuring device, e.g., milling files for deep engraving, and data transmitted to the coating device, e.g., separate print files.Particularly preferably, the optimal position of the three-dimensionally structured surface and the decoration relative to one another is determined by means of a fiducial mark in the data. A fiducial mark is an identical reference mark contained in at least two corresponding data sets of the structuring device and the coating device, which ensures that the decoration and the three-dimensionally structured surface are superimposed as intended when the decorative element is produced on the basis of these data sets, so that the fiducial marks or reference marks lie one above the other. For example, this reference mark can be embossed into the surface together with the structuring. However, the reference mark can also be produced before or after structuring. This can then preferably take place very shortly before or after the structuring is produced, preferably without intermediate transport of the carrier element.Such a procedure is suitable, for example, if the structuring is produced by laser processing. Since the laser beam always works in a point-like manner, the structuring and the reference mark are necessarily produced sequentially unless multiple lasers are used. The structuring and the reference mark are then preferably produced in a single setup. However, an intermediate transport of the carrier element can also be used. Preferably, the already produced structuring is first detected and, if necessary, measured in order to then produce the reference mark to match it. Such detection can also be combined with other quality assurance steps, purely for example via image recognition of the produced structuring. The detection and, if necessary,If necessary, measurement can be repeated after the reference mark has been produced to verify that the produced reference mark actually has the predetermined geometric relationship to the structure. This also ensures highly accurate production of the reference mark.

[0033] The reference mark can, for example, comprise a crosshair, a crosshair triangle, or even crosshairs with different edge lengths. However, it can also simply comprise a hole or be designed as a see-through register.

[0034] The produced reference mark has a predetermined geometric relationship with the structuring, at least with respect to its position on the carrier element. Such a relationship can preferably comprise a defined distance between the reference mark and the structuring in the longitudinal and transverse directions on the carrier element. Since the structuring has a known shape, the position of the reference mark has a predetermined geometric relationship with the structuring as a whole and with each of its structural elements. Therefore, the distance of the reference mark from individual structural elements can easily be deduced from the defined distance between the reference mark and the structuring as a whole.

[0035] The structuring can be a pattern that repeats periodically on the carrier element (in the sense of continuous structuring). The position of the reference mark, with its predetermined geometric relationship, can then also refer to only one period of the pattern, for example. Preferably, one reference mark is then produced for each period, which is then recognized by the coating device, for example, for printing the respective period. A period length can therefore preferably be tailored to the coating device's process, which usually only has a limited working space available in which the period can be printed.

[0036] Preferably, the reference mark also has a predetermined geometric relationship with the structuring with respect to its orientation on the carrier element. Such a relationship can preferably include a parallel alignment of the reference mark and the structuring on the carrier element.

[0037] To include such geometric relationships, reference marks with a clear orientation are preferred, for example an isosceles triangle whose length is greater than its width or a crosshair with different edge lengths.

[0038] In this way, the accuracy of the fit of the decoration to the structure can be further increased.

[0039] The reference mark can also have a predetermined geometric relationship with the structuring in terms of its size on the carrier element. For example, the reference mark can represent a size scale relative to the structuring. The size scale can be represented both longitudinally and transversely on the carrier element and even in depth. For example, the reference mark can be embossed into the carrier layer to a defined depth, allowing inferences to be made about the depth of the structuring.

[0040] All this can be used in addition to control the application of the decoration to the three-dimensional structure, so that the accuracy in the fit of the decoration to the structure is further increased and random interference can be compensated even better.

[0041] In principle, the reference mark can also be integrated into the structuring. The structuring can then, for example, deviate locally from the otherwise natural wood grain in favor of the geometric manufacturing accuracy required for the reference mark.

[0042] In particular, after the reference mark has been created, the decoration is applied to the structure in a predetermined geometric relationship to it. This ensures the intended optical interaction of 3D structuring and coloring. For this purpose, the reference mark is recognized, and from this, at least the relative position to the structure is deduced, so that the decoration can be applied to the structure, for example, congruently. In particular, this advantageously allows certain color areas of the decoration to be applied very precisely to specific areas of the structure intended for this purpose, and random interference can be compensated for.

[0043] Analogous to what was said above, conclusions can also be drawn about the relative orientation or the size of the structuring in order to further increase the accuracy of the process.

[0044] For this purpose, the coating device preferably comprises a suitable detection system, particularly preferably an optical measuring system such as a camera or a laser measuring system. For the sake of completeness, it should be noted that, in principle, a tactile measuring system could also be used to scan the reference mark.

[0045] Particularly preferably, the determined relative position and, if necessary, also the determined relative orientation are evaluated in at least one of their temporal derivatives. This makes it particularly advantageous to infer the relative speed or acceleration of the structuring device relative to the coating device, which allows for particularly effective compensation of disruptive influences such as speed fluctuations at the structuring device.

[0046] This is particularly advantageous, for example, in a manufacturing flow process to adapt a production speed of the coating device to a production speed of the upstream structuring device or to synchronize the production speeds.

[0047] Depending on the material of the substrate, a variety of coating processes can be considered, such as spraying, printing, or conventional printing plates or rollers. In principle, the process must be suitable for applying ink or color pigments to the structure as intended. However, digital printing processes are particularly preferred.

[0048] Jet printing is the preferred digital printing process. These are suitable for both malleable materials such as wood or plastic, as well as hard materials such as ceramic or stone.

[0049] Based on the present disclosure, the person skilled in the art is able to independently select suitable structuring and coating methods, taking into account the specific material of the carrier element, the complexity of the structuring to be produced and the corresponding decoration to be produced.

[0050] It should also be noted that flexible structuring and coating devices can also be used. For example, a structuring device can be used that includes an embossing tool change system to produce different structures. This is also possible with jet processes, for example. In combination with a digital printing device, this offers particular advantages, as different three-dimensionally structured decorative elements can be flexibly produced.

[0051] Following coating, the surface of the decorative element can optionally be coated or sealed, for example, to ensure protection against wear in a floor covering. In a preferred embodiment of the method of the invention, the structuring device and the coating device are connected to one another in a flow-through production process, and a relative speed of the three-dimensionally structured surface to the coating device is determined from the determined relative position and used to adapt a production speed of the coating device to a production speed of the structuring device.

[0052] Since random effects such as material jamming, slippage, or even transverse and longitudinal contraction of the material can occur during the structuring process, the production speed at the structuring device can fluctuate. At the same time, the application process at the coating device represents a particularly quality-relevant process step. Due to the described synchronization of production speeds, the structuring device essentially takes the lead in controlling flow production. Unexpected changes in the material flow can thus be effectively compensated for at the coating device.

[0053] Flow production can be either intermittent or continuous, with the reference mark being detected before or at the coating device, and the speed of the reference mark (and thus of the decoration) controlling the coating process. For intermittent flow production, embossing plates, for example, are also suitable for producing the structuring, whereas embossing rollers are preferred in continuous flow production.

[0054] In a further preferred embodiment of the method of the invention, it is provided that the structuring device and the coating device are connected to one another in a material buffer for continuous production, wherein a production speed at the coating device and a production speed at the structuring device are decoupled, and a relative speed of the three-dimensionally structured surface to the coating device is determined from the determined relative position and used to control the production speed of the coating device. Since random effects such as material jamming, slippage, or transverse and longitudinal contraction of the material can occur during the structuring process, the production speed at the structuring device can fluctuate, as mentioned above.At the same time, as mentioned, the application process at the coating device represents a particularly quality-relevant process step. Due to the buffering of the material after the structuring device, unexpected changes in the material flow can be effectively compensated at the coating device and the production speed of the coating device can be controlled, for example, based on the feed speed of the material from the material buffer.

[0055] Buffered through-feed production can be carried out intermittently or continuously, with the reference mark being detected before or at the coating device, and the speed of the reference mark (and thus of the decoration) controlling the coating process. For intermittent through-feed production, embossing plates, for example, are also suitable for producing the structuring, whereas embossing rollers are preferred for continuous through-feed production.

[0056] The carrier element can basically be present as a piece material or can also be supplied to the process of the invention as a continuous material.

[0057] In a preferred embodiment of the method of the invention, it is provided that the structuring device produces the three-dimensionally structured surface by forming and / or separating.

[0058] A forming process, such as embossing, is preferred here, as there is no material loss and the process can be carried out very quickly and precisely. However, this is not possible for some materials, such as stone. In such cases, a separation process is used. In a preferred embodiment of the method of the invention, the coating device applies the decoration using digital printing, as this printing technique is particularly flexible.

[0059] In a preferred embodiment of the method of the invention, it is provided that the reference mark and the three-dimensionally structured surface are produced simultaneously.

[0060] The marking device can then preferably be integrated into the structuring device. Particularly preferably, the structuring and the production of the reference mark are then carried out together by forming.

[0061] In an alternative preferred embodiment of the method of the invention, it is provided that either the reference mark is produced before the three-dimensionally structured surface and the reference mark is measured at least once before the three-dimensionally structured surface is produced, or that the three-dimensionally structured surface is produced before the reference mark and the three-dimensionally structured surface is measured at least once before the reference mark is produced.

[0062] This is particularly useful for processes where simultaneous structuring and production of the reference mark is difficult, such as in blasting processes or when separate structuring and marking devices are to be used for other reasons. It is also useful when material transport is required between structuring and production of the reference mark.

[0063] According to the invention, the measurement of the reference mark or the three-dimensionally structured surface is carried out at least with respect to its position, so that the respective other element (reference mark / structuring) can be positioned in a defined manner relative to it. The relative positioning can be fixedly predetermined or flexibly defined. In the latter case, the determined relative positioning is expediently transferred to the coating device so that, after detecting the reference mark, it can deduce the location of the structuring. All of this can be implemented, for example, via a common control unit.

[0064] To further increase the accuracy, the reference mark or the structuring can also be measured with regard to its orientation or size in order to define the orientation or dimension of the other element relative to it.

[0065] In a preferred embodiment of the method of the invention, in which the reference mark and the three-dimensionally structured surface are preferably produced simultaneously, it is provided that a reference structure resulting from the three-dimensionally structured surface is at least partly used as the reference mark. Particularly preferably, the reference mark is produced simultaneously with the three-dimensionally structured surface, and a reference structure resulting from the three-dimensionally structured surface is used as the reference mark.

[0066] For this purpose, all reference structures contained in the three-dimensionally structured surface that are sufficiently geometrically defined are considered. The necessary accuracy of such reference structures results from the required accuracy in positioning the decor relative to the three-dimensionally structured surface using the downstream coating device. For example, the reference structure could be a horizontal and a vertical groove (e.g., representative of cracks in wood) that are sufficiently straight and perpendicular to each other to serve as a reference mark. As already mentioned above, such reference structures can also be specifically incorporated into the design of the three-dimensionally structured surface.In such embodiments of the method, the structuring device can also be regarded as a marking device, since it produces both the three-dimensionally structured surface and the reference structure or reference mark contained therein.

[0067] Furthermore, reference structures of the three-dimensionally structured surface can also serve only as part of a reference mark, with another part of the reference mark still being produced separately with the marking device.

[0068] A further aspect of the invention relates to a three-dimensionally structured decorative element produced in a method according to the invention according to the present disclosure.

[0069] Preferably, this is a floor covering element.

[0070] A further aspect of the invention relates to a production system designed to carry out a method according to the invention according to the present disclosure.

[0071] Preferably, the production system of the invention is designed and configured to carry out the method according to the invention.

[0072] A further aspect of the invention relates to a control device designed and configured to carry out a method according to the invention in accordance with the present disclosure.

[0073] The control device of the invention is preferably designed and configured to control a production system according to the invention. Particularly preferably, the control device is capable of controlling the structuring device, the marking device, the coating device, and any detection or measuring systems, and of processing their data.

[0074] With regard to possible embodiments of the three-dimensionally structured decorative element according to the invention, as well as of the production system and control device according to the invention, it is noted that all features of these devices or products of the invention disclosed in the description of the method according to the invention are also disclosed as their independent features in possible embodiments. Analogously, any method features disclosed with respect to the aforementioned devices or products according to the invention are also disclosed as independent features of possible embodiments of the method according to the invention.

[0075] In principle, all features disclosed herein with reference to a specific embodiment can also be combined with other embodiments of the invention. This applies in particular to individual features, unless explicitly stated herein that an inextricable functional-technical connection exists between certain features that must be maintained to implement the invention.

[0076] The invention is explained below using exemplary embodiments and schematic drawings. Herein:

[0077] Figure 1 shows the sequence of a method according to the invention using a production system according to the invention;

[0078] Figure 2 Reference marks in different variants; and

[0079] Figure 3 shows a three-dimensionally structured decorative element according to the invention.

[0080] Figure 1 shows the sequence of a method according to the invention for producing a three-dimensionally structured decorative element 10, purely by way of example using a production system 12 according to the invention.

[0081] The production system 12 comprises a structuring device 14, a marking device 16, and a coating device 18, which will be discussed in more detail later. The production system 12 further comprises a control unit 20, which is designed and configured here according to the exemplary production system 12 to control the production system 12 to carry out the method according to the invention. For this purpose, the control unit 20 exchanges data 60 with the respective devices 14, 16, 18, or even other subsystems of the production system 12 as needed.

[0082] The method according to the invention for producing the three-dimensionally structured decorative element 10 comprises a first step in which a carrier element 22 is provided. In this example, the carrier element 22 is, by way of example, a floor covering blank made of a vinyl material or a laminate comprising vinyl material. Accordingly, in this exemplary embodiment, a three-dimensionally structured floor covering element 24 is produced as a three-dimensionally structured decorative element 10. The carrier element 22 is provided here, by way of example, as a continuous material and fed to the structuring device 14 in the direction indicated by the thick arrow at the left end of the decorative element 10.

[0083] In a second step, a three-dimensionally structured surface 26 is then produced on the carrier element 22 in the structuring device 14. In this exemplary embodiment, the structuring device 14 produces the three-dimensionally structured surface 26, for example, by forming. For this purpose, in this embodiment, it comprises a roller 28 with which the three-dimensionally structured surface 26 is embossed into the carrier element 22. In other embodiments, the three-dimensionally structured surface 26 can be produced using an embossed press plate. In this example, the three-dimensionally structured surface 26 corresponds to a natural wood surface, which has typical cracks 30 or knots 32 (see Figure 3).

[0084] In this embodiment, a third step is performed simultaneously with the second step, although in other embodiments, it can also be performed at a different time. In the third step, a reference mark 34 (see Figures 2 and 3) is embossed into the carrier element 22 using the roller 28 together with the three-dimensionally structured surface 26. The produced reference mark 34 has a predetermined geometric relationship with the produced three-dimensionally structured surface 26 with respect to its position 36 (see Figure 3) on the carrier element 22.

[0085] Before going into this in more detail, the reference mark 34 itself will be explained more clearly using Figure 2. Figure 2 shows three exemplary variants of the reference mark 34. On the left, for example, a reference mark 34 is illustrated as a crosshair with different edge lengths 38. Due to the different edge lengths 38, this reference mark 34 can also be assigned a unique orientation. In the middle, a reference mark 34 is illustrated as a crosshair with the same edge lengths 40. Since these always look the same at 90° intervals, only a limited orientation can be derived from such a reference mark 34. In flow processes, such as the one at hand, this is often sufficient, since the orientation of the carrier element 22 can only change in small areas during the material flow anyway. On the right in Figure 2, another reference mark 34 is illustrated as an isosceles triangle 42, which also has a unique orientation.

[0086] Following on from the explanation of Figures 1 and 3, in this exemplary embodiment, the reference mark 34 is assumed to be a crosshair with equal edge lengths 40. This can also be seen at the top left in Figure 3. The predetermined geometric relationship between the position 36 of the reference mark 34 and the position 37 of the three-dimensionally structured surface 26 refers to each element of the three-dimensionally structured surface 26, such as the crack 30 or the branch attachment 32. In other words, the position 36 of the reference mark 34 can be uniquely described in the specific coordinate system of the three-dimensionally structured surface 26, and therefore, recursively, each position 39 of any element of the three-dimensionally structured surface 26, starting from the position 36 of the reference mark 34.Figure 3 shows by way of example that the position 36 of the reference mark 34 on the carrier element 22 has, for example, a defined distance from the branch attachment 32 in the longitudinal direction 44 and transverse direction 46 on the carrier element 22.

[0087] The three-dimensionally structured surface 26 can be present as a periodically repeating pattern in the sense of a continuous structuring. For example, Figure 3 can be interpreted as showing a section 45 of the periodic pattern or the three-dimensionally structured surface 26, which is repeated in the longitudinal direction 44, for example, every three subsequent sections (not shown). In the example shown, the reference mark 34 is therefore located within the section 45 of the pattern corresponding to it.

[0088] In the present example, the process is carried out as a flow production process, in the direction indicated by the thick arrow at the left end of the decorative element 10. Thus, the roller 28 continuously or intermittently produces the three-dimensionally structured surface 26 with the reference mark 34, here, for example, in periodically recurring sections 45 according to Figure 3 on the carrier element 22.

[0089] After leaving the structuring device 14, such a section 45 of the carrier element 22 with the produced three-dimensionally structured surface 26 and the produced reference mark 34 passes, in a fourth step, a recognition system 48 of the production system 12. The recognition system 48 is implemented here as an example as an optical measuring system in the form of a camera 49 and can also exchange data 60 with the control unit 20. The recognition system 48 detects the reference mark 34 (cf. Figure 2) and can thereby determine a relative position 50 of the reference mark 34 to the coating device 18. The recognition system 48 can also be integrated directly into the coating device 18. Since the position 36 of the reference mark 34 relative to each element of the three-dimensionally structured surface 26 is known, the determined relative position 50 of the reference mark 34 to the coating device 18 also provides the relative position of each element (e.g.Reference numerals 30 and 32) of the three-dimensionally structured surface 26 to the coating device 18. For the branch attachment 32, the calculation of the relative position to the coating device 18 would be simplified here, for example, the relative position 50 of the reference mark 34 to the coating device 18 vectorially added to the position 36 of the reference mark 34 relative to the branch attachment 32.

[0090] In a fifth step, a decoration 52 is then applied to the three-dimensionally structured surface 26 using the coating device 18. The decoration 52 corresponds to a color layer equivalent of the three-dimensionally structured surface 26 shown in Figure 3. The reference mark 34 is used to determine the relative position 50 of the three-dimensionally structured surface 26 to the coating device 18 and to apply the decoration 52 in a predetermined geometric relationship to the three-dimensionally structured surface 26. The predetermined geometric relationship includes, in particular, applying the appropriate color areas of the decoration 52 to the corresponding elements (e.g., reference numerals 30 and 32) of the three-dimensionally structured surface 26, for example, to naturally color the crack 30 and the branch 32. It should be noted that the reference mark 34 is shown in Figure 3 for clarity of illustration.However, if necessary, this can be overlaid by the decoration 52 so that it is no longer visible on the finished decorative element 10.

[0091] The state shown in Figure 3 thus shows the intended combination of the three-dimensionally structured surface 26 and the decoration 52, which are congruently connected to one another.

[0092] A digital printing process is preferably used to apply the decoration 52.

[0093] It has already been mentioned that the structuring device 14 and the coating device 18 are connected to one another in the sense of flow production. Particularly advantageously, a relative speed 54 and, if necessary, a relative acceleration 55 of the three-dimensionally structured surface 26 relative to the coating device 18 can be determined from the determined relative position 50. The relative speed 54 can be used to adapt a production speed 56 of the coating device 18 to a production speed 58 of the structuring device 14 (this applies analogously to relative accelerations).

[0094] For this purpose, the detection system 48 can be equipped with several, for example, two, cameras 49, 51, as shown in Figure 1, to improve detection accuracy. However, the detection system 48 can also be integrated only into the coating device 18, for example, with the camera 51. The spatial proximity to the coating device 18 significantly improves the possibility of synchronizing the production speed 56 at the coating device 18 and the production speed 58 at the structuring device 14.

[0095] In principle, however, the detection system 48 can also be arranged only between the coating device 18 and the structuring device 14 or between the marking device 16 and the coating device 18.

[0096] It should also be noted that the arrangement of the recognition system 48 shown in Figure 1 is also particularly well suited for other process variants in which the three-dimensionally structured surface 26 is produced in front of the reference mark 34.

[0097] In such an alternative embodiment of the method, it is preferred that the three-dimensionally structured surface 26 is measured at least once before the reference mark 34 is produced, so that the reference mark 34 is positioned as intended relative to the three-dimensionally structured surface 26. In such methods, the marking device 16 can be provided as a separate device, for example, between the camera 49 shown in Figure 1 and the coating device 18, in order to measure the three-dimensionally structured surface 26.

[0098] The coating device 18 then additionally has the camera 51 for detecting the reference mark 34.

[0099] In principle, after the decorative element 52 has been produced, a sealant 62 can optionally be applied to the decorative element 52, for example, to protect the floor covering element 24 against wear. For this purpose, the production system 12 can include an optional sealing device 64.

[0100] List of reference symbols

[0101] 10 three-dimensional structured decorative element

[0102] 12 Production system

[0103] 14 Structuring device

[0104] 16 Marking device

[0105] 18 Coating device

[0106] 20 Control unit

[0107] 22 support element

[0108] 24 floor covering element

[0109] 26 three-dimensional structured surface

[0110] 28 rollers

[0111] 30 crack

[0112] 32 branch attachment

[0113] 34 Reference mark

[0114] 36 Position (of the reference mark)

[0115] 37 Position (of the three-dimensional structured surface)

[0116] 38 crosshairs with different edge lengths

[0117] 39 Position (of the branch base)

[0118] 40 crosshairs with equal edge lengths

[0119] 42 isosceles triangle

[0120] 44 Longitudinal direction (of the support element)

[0121] 45 Section (of the three-dimensional structured surface)

[0122] 46 Transverse direction (of the support element)

[0123] 48 detection system

[0124] 49 Camera

[0125] 50 Relative position (reference mark to the coating device)

[0126] 51 Camera

[0127] 52 Decor

[0128] 54 Relative speed (reference mark to the coating device)

[0129] 55 Relative acceleration (reference mark for the coating device)

[0130] 56 Production speed (of the coating device)

[0131] 58 Production speed (of the structuring device)

[0132] 60 Data 62 Sealing

[0133] 64 Sealing device

Claims

Patent claims Method for producing a three-dimensionally structured decorative element (10), comprising the following steps: - Providing a support element (22); - Production of a three-dimensionally structured surface (26) on the support element (22) using a structuring device (14); - Production of at least one reference mark (34) on the carrier element (22) with a marking device (16), wherein the produced reference mark (34) is in a predetermined geometric relationship (44; 46) with the produced three-dimensionally structured surface (26) at least with respect to its position (36) on the carrier element (22); and thereafter - Applying a decoration (52) to the three-dimensionally structured surface (26) using a coating device (18), wherein at least one relative position (36; 37; 50) of the three-dimensionally structured surface (26) to the coating device (18) is determined and used based on the reference mark (34) to apply the decoration (52) in a predetermined geometric relationship to the three-dimensionally structured surface (26).A method according to claim 1, characterized in that the structuring device (14) and the coating device (18) are connected to each other in a flow production manner, and that a relative velocity (54; 55) of the three-dimensionally structured surface (26) to the coating device (18) is further determined from the determined relative position (36; 37; 50) and used to adapt a production speed (56) of the coating device (18) to a production speed (58) of the structuring device (14). A method according to any of the preceding claims, characterized in that the structuring device (14) and the... The coating unit (18) is connected in a material buffer in the sense of continuous production, wherein a production speed (56) at the coating unit (18) and a production speed (58) at the structuring unit (14) are decoupled and a relative speed (54; 55) of the three-dimensionally structured surface (26) to the coating unit (18) is further determined from the determined relative position (36; 37; 50) and used to control the production speed (56) of the coating unit (18).

4. Method according to one of the preceding claims, characterized in that the structuring device (14) produces the three-dimensionally structured surface (26) by forming and / or separating.

5. Method according to one of the preceding claims, characterized in that the coating device (18) applies the decoration (52) by digital printing.

6. Method according to one of the preceding claims, characterized in that the reference mark (34) and the three-dimensionally structured surface (26) are produced simultaneously.

7. Method according to one of claims 1 to 5, characterized in that either the reference mark (34) is produced before the three-dimensionally structured surface (26) and the reference mark (34) is measured at least once before the three-dimensionally structured surface (26) is produced, or that the three-dimensionally structured surface (26) is produced before the reference mark (34) and the three-dimensionally structured surface (26) is measured at least once before the reference mark (34) is produced.

8. Method according to one of the preceding claims, characterized in that the reference mark (34) is a designation derived from the The reference structure resulting from the three-dimensionally structured surface (26) is at least partially used. Three-dimensionally structured decorative element (10), manufactured in a method according to any one of claims 1 to 8. Three-dimensionally structured decorative element (10) according to claim 9, characterized in that it is a three-dimensionally structured floor covering element (24). Production system (12), configured for carrying out a method according to any one of claims 1 to 8. Control unit (20), configured and set up for carrying out a method according to any one of claims 1 to 8 with a production system (12) according to claim 11.

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