Method for producing decorated plates, in particular derived from wood material plates and a plurality of decorated plates

Abstract

The invention relates to a method for producing decorated panels (24), in particular wood-based panels, in which carrier panels (20) with a carrier panel length (LT) are provided, in which each carrier panel (20) is provided with a decoration, the decoration being repeated after a decoration image length (LD) in accordance with a repeat, which is characterized in that the decoration image length (LD) in units of the carrier panel length (LT) lies in one of the intervals [(n* 0.5+x)*LT; ((n+1)*0.5-y)*LT] with n from the interval [0 ... 5] and x, y greater than 0.05 and less than 0.3. The object of achieving a larger number of differently decorated panel parts after dividing decorated panels (24) is thereby achieved. The invention also relates to a plurality of decorated panels.

Description

[0001] The invention relates to a method for producing decorated panels for furniture or doors, in particular wood-based panels, as well as a plurality of decorated panels.

[0002] The decorated panels for furniture or doors typically have a wood-based panel as the core board, which is coated with one or more layers of paper, paint, or varnish. In particular, a printed decorative paper is used to create a decoration on one of the two upper surfaces. This decorative paper can also be coated with at least one additional overlay layer to increase abrasion resistance. Instead of decorative paper, a decoration can also be printed onto the core board.

[0003] Instead of a wood-based panel, a panel made of another material can also be used. For example, panels made of plastic, a wood-based material-plastic mixture or a natural material such as cork can also be provided with a decoration.

[0004] The size of the slabs of the type primarily of interest here ranges from dimensions of more than 1.4 meters. For example, the slabs are manufactured in a length of 5.6 m and a width of 2.08 m and then divided into slabs approximately 2.8 m long. These slabs are also known as half-format slabs, which, after production, are divided into smaller slabs of standard sizes. The general goal is for the half-format slab to have a decor that creates the most varied appearance possible, both as a whole and in the divided smaller slabs.

[0005] The repeat pattern of the decorative print is a crucial factor for achieving the most diverse appearance possible. Repeat printing involves a continuously repeating print image without any visible interruption. This process is used for both continuous print images and decorative printing.

[0006] The term "pattern repeat" refers to a pattern that is constantly repeated during continuous printing, the repetition of which creates the entire design. A pattern repeat is characterized by the pattern length and pattern width.

[0007] By default, the decorative pattern length, i.e., the repeat length, is approximately 1.4 m, which corresponds to a quarter of the 5.6 m core panel length or half the length of the half-format. Therefore, all half-formats or panels have the same decorative pattern. If the half-formats are always split in the same way and panel sections with smaller dimensions are created, the panel sections resulting from a half-format will have a similar appearance. If the panel sections are combined to form a larger surface, the repeating patterns of the individual panel sections can be noticeable when examining the component, such as a piece of furniture or a door.

[0008] EP 4 215 383 A1 discloses selecting a repeat length or decorative length greater than twice the length of the carrier board, which is also referred to as the core of the decorative component to be manufactured. While this achieves greater decorative variety in the decorative components, identical board parts still appear after separation.

[0009] EP 1 908 608 A1 discloses a method for producing decorative components in which the repetition frequency of a surface structure is different from the repetition frequency of the decoration. Since the surface structure and the printed decoration together determine the decorative image, the number of different decorated panels is increased. This method is also particularly suitable for smaller component dimensions of half-formats.

[0010] EP 2 253 470 A1 describes two different printing rollers that can be moved independently into printing and rest positions. Therefore, this application is limited to a single gravure printing process, and the variety of decorated plates is created by varying the pressure ratios of the various printing rollers.

[0011] The methods known to date for producing decorated panels have therefore not yet provided a satisfactory solution to the problem of producing as many differently decorated panels as possible while taking the pattern repeat into account.

[0012] Therefore, the object of the present invention is to achieve a larger number of differently decorated half-formats and thus also of differently decorated panel parts after dividing decorated half-formats.

[0013] The above-mentioned object is achieved according to the invention by a method for producing decorated panels, in particular wood-based panels, in which carrier panels with a carrier panel length (LT) are provided and in which each carrier panel is provided with a decoration, wherein the decoration is repeated after a decoration image length (LD) corresponding to a repeat. The method is characterized in that the decoration image length (LD) in units of the carrier panel length (LT) lies in one of the intervals [(n* 0.5+x)*LT; ((n+1)*0.5-y)*LT] with n = 0 ... 5 and x, y greater than 0.05 and less than 0.3. Here, n is an integer and x and y are real numbers.

[0014] Examples of intervals are: [0.3; 0.45]*LT, [0.55; 0.95]*LT, [1.05; 1.45]*LT, [1.55; 1.95]*LT [0.35; 0.4]*LT, [0.6; 0.9]*LT, [1.1; 1.4]*LT, [1.6; 1.9]*LT

[0015] Because, according to the invention, the intervals avoid integer multiples of 0.5, each with a range specified by x and y, there is a sufficiently large offset of the decorations between any two consecutive decorations during the production of the decorated panels, so that the decorated panels as half-formats, and thus also the panel parts after the decorated panels have been separated into individual panel parts, differ far more significantly and more frequently in their decorations than if the integer multiples of 0.5 were included. This has the advantage of allowing a larger number of panels with different appearances to be produced.

[0016] After the panel parts have been installed, for example as a piece of furniture or as a door, it is less likely that two panel parts combined in any way will have the same appearance.

[0017] A decoration within the scope of this invention is a decoration that reproduces a natural surface. The decoration can therefore be a reproduction of a plant material, in particular a wood decoration. However, the decoration can also be a reproduction of a stone surface.

[0018] Preferably, n has a value in the interval [1 ... 5]. This has the advantage that if the carrier board with length LT has been divided into a half-format with a length of 0.5 * T, the half-format already has no repeating decorative areas before being divided into board parts.

[0019] For example, the carrier boards to which the decoration is applied can have a carrier board length of the order of magnitude of 5.6 m. Immediately after the decoration has been applied by pressing a decorative paper, the coated boards are halved so that the resulting board sections, also known as half-format boards, have a length of 2.8 m. In this way, boards (half-formats) with a decorative image length greater than 2.8 m are produced. If n has a value from the interval [1 ... 5], the decorative image length is greater than the half-format board length and there are no repetitions of certain image sections on a decorative half-format board. In addition, the subsequently divided smaller board sections, as components, all have different image sections.

[0020] A method in which the decoration is produced without a decorative jump is also preferred. Thus, no jump, i.e., an interruption in the decoration, is visible when the repeat is reached. This applies particularly to the longitudinal direction of the decoration, but can also be provided in the width direction.

[0021] The material of the core boards is preferably particleboard, oriented strand board (OSB), medium-density fiberboard (MDF), or high-density fiberboard (HDF). However, the core board can also be made of plastic, a wood-based plastic blend, or a natural material such as cork. The core board can also preferably be made of laminated boards, compact boards, or several core papers pressed together.

[0022] There are various ways to apply the decoration to the carrier plate.

[0023] Preferably, a paper web is printed with a decoration. The printed paper web is then cut into decorative paper layers (sheets), the dimensions of the decorative paper layers corresponding to the dimensions of the carrier board. The decorative paper layer and the carrier board, as well as any additional layers, are pressed together under the influence of pressure and temperature to form a decorated board. Additional layers can include overlay papers, counter-papers, core papers (kraft papers), or one or more coating layers applied before or after pressing.

[0024] Furthermore, the method can be carried out in which a paper web is printed with a decoration, in which the printed paper web is pressed together with several resin-impregnated paper layers in a continuous press under application of pressure and temperature to form a decorative laminate, in which the decorative laminate is cut into individual panels, which can also be referred to as sheets, after pressing, wherein the dimensions of the laminate panel correspond to the dimensions of the carrier panel, and in which the carrier panel is coated with the decorative laminate panel.

[0025] The order of the last two steps is also reversible, whereby firstly adjacent carrier plates are coated with the continuous decorative laminate plate, in particular with a decorative laminate plate unrolled from a roll, and whereby the decorative laminate is then cut open after pressing according to the division of the carrier plates, whereby the dimensions of the respective laminate plate then correspond to the dimensions of the carrier plate.

[0026] Likewise, in the production of laminated or compact panels, the decorative layer can be pressed together with the other underlying layers in a single process. In this case, the upper layer of the laminated or compact panel represents the decorative layer, and the underlying layers represent the carrier board.

[0027] During the pressing process, a surface structure can also be pressed into the surface, particularly synchronously with the optical decoration.

[0028] It is also possible to apply the decoration to the carrier plate as a direct print, in particular using digital printing or gravure printing processes.

[0029] Furthermore, the carrier board can have a carrier board length (LT) in the range of 2.6 to 5.8 m and / or a carrier board width of 1.8 to 2.5 m. This determines the format that must be considered with regard to the repeat length. According to the intervals described for the permitted decorative image lengths in units of the carrier board lengths, the repeat length must be selected to be relatively long.

[0030] Furthermore, the width of the decorative image preferably corresponds to the width of the carrier board. This eliminates any repetitions in the direction of the decorative width.

[0031] The above-mentioned object is also achieved according to the invention by a plurality of decorated panels with carrier panels having a carrier panel length (LT) and with a surface layer connected to the carrier panels with a decoration, wherein the decoration repeats after a decoration image length (LD) corresponding to a repeat. The plurality of decorated panels is characterized in that the decoration image length (LD) in units of the carrier panel length (LT) lies in one of the intervals [(n* 0.5+x)*LT; ((n+1)*0.5-y)*LT] with n = 0 ... 5 and x, y greater than 0.05 and less than 0.3.

[0032] Preferably, the plurality of decorated plates are formed with one or more of the features described above for the method.

[0033] In the following, the invention is explained using exemplary embodiments with reference to the drawing. In the drawing, Fig. 1 a printing device for printing a decorative paper web with a repeating decoration and Fig. 2a-c a schematic representation of the different divisions of the decorative image lengths and carrier plate lengths.

[0034] Fig. 1 shows a printing device 2 for printing a paper web 4, which is unrolled from a roll 6 and, after printing, forms a long web 8 of a decorative paper 10. The decoration is designed as a replica of a wood grain.

[0035] The decoration 12 produced by the printing device 2 has a decoration image length LD, so that at the end of each decoration image length LD the decoration pattern is repeated, which is designed here as an example and for the sake of clarity as a reproduction of a natural wood grain pattern. For better identification, the transition from the end of the decoration after the decoration length LD to the next beginning of the repeating decoration is shown with an interruption in the grain. This makes the decoration length LD clearer in addition to the dashed line between two identical decoration sections. However, in the production of decorated panels, a decoration is usually used which at the end transitions seamlessly into the repetition of the decoration at the beginning.

[0036] Fig. 2a shows a plurality of decorative panels 24 known from the prior art, in each of which a carrier panel 20 with a carrier panel length LT was coated with a decor with a decor image length LD, wherein the decor image length LD is selected to be the same as the carrier panel length LT. Therefore, each of the resulting decorated panels 24 has the same decor, so that a plurality of decorated panels 24 with a largely identical appearance are produced. During further use of the decorated panels 24, the decor is repeated in the same places, which influences the visual impression. This is because the design is often repeated in the same places, which reduces the natural impression, since panels made from natural materials do not have such a repetition effect.

[0037] The Fig. 2b und 2c show a plurality of decorated panels 24 as obtained by applying the method according to the invention. Carrier panels 20 with a carrier panel length LT are provided, and each carrier panel 20 is provided with a decoration, wherein the decoration is repeated after a decorative pattern length LD corresponding to a repeat.

[0038] Generally speaking, the decorative image length LD in units of the carrier plate length LT lies in one of the intervals [ (n* 0.5+x)*LT; ((n+1)*0.5-y)*LT ], where n = 0 ... 5 and x, y are chosen to be greater than 0.05 and less than 0.3.

[0039] For example, if LD = 1.11 * LT, then the identical decoration is very rarely repeated on the carrier plates, resulting in a very large set of differently decorated carrier plates.

[0040] In Fig. 2b corresponds to LD = 1.25 * LT. The decoration is therefore repeated every fifth decorated plate 24, with the decoration having a greater decoration length LD than the carrier plate length LT and therefore no sections of the decoration are repeated on a decorated plate 24.

[0041] Fig. 2c shows a plurality of decorated plates 24, where LD = 0.9 * LT. Therefore, the decoration is repeated only every eleventh decorated plate 24, which lies outside the range shown in Fig. 3c. The decoration has a smaller decoration length LD than the carrier plate length LT, and sections of the decoration are repeated on a decorated plate 24.

Claims

1. A method for producing decorated panels (24) for furniture or doors, wherein the decoration reproduces a natural surface, - in which carrier panels (20) are provided with a carrier panel length (LT) and - in which each carrier panel (20) is provided with a decoration, wherein the decoration is repeated after a decoration image length (LD) corresponding to a repeat, characterized by - that the decorative image length (LD) in units of the carrier plate length (LT) in one of the intervals [(n* 0.5+x)*LT; ((n+1)*0.5-y)*LT ] lies with n from the interval [0 ... 5] and x, y greater than 0.05 and less than 0.

3.

2. Method according to claim 1, wherein the decorative image length (LD) in units of the carrier plate length (LT) lies in one of the intervals with [0.3; 0.45]*LT, [0.35; 0.4]*LT, [0.55; 0.95]*LT, [0.6; 0.9]*LT, [1.05; 1.45]*LT, [1.1; 1.4]*LT, [1.55; 1.95]*LT or [1.6; 1.9]*LT.

3. The method according to claim 1 or 2, wherein n has a value from the interval [1 ... 5].

4. Method according to one of claims 1 to 3, in which the decoration is produced without a decorative jump.

5. Method according to one of claims 1 to 4, - in which a paper web (4) is printed with a decoration, - in which the printed paper web (8) is cut into decorative paper layers, the dimensions of the decorative paper layers corresponding to the dimensions of the carrier plate (20), - in which the decorative paper layer and the carrier plate (20) and optionally further layers are pressed under the influence of pressure and temperature to form a decorated plate (24).

6. Method according to one of claims 1 to 4, - in which a paper web (4) is printed with a decoration, - in which the printed paper web (8) is pressed together with several resin-impregnated paper layers in a continuous press using pressure and temperature to form a decorative laminate, - in which the decorative laminate is cut into individual sheets after pressing, the dimensions of the laminate sheet corresponding to the dimensions of the carrier sheet (20), and - in which the carrier sheet (20) is coated with the decorative laminate sheet.

7. Method according to one of claims 1 to 4, - in which a paper web (4) is printed with a decoration, - in which the printed paper web (8) is pressed together with several resin-impregnated paper layers in a continuous press under the application of pressure and temperature to form a decorative laminate, - in which adjoining carrier plates (20) are coated with the continuous decorative laminate plate, in particular with a decorative laminate plate unrolled from a roll, and - in which the decorative laminate is cut open after pressing in accordance with the division of the carrier plates (20), the dimensions of the respective laminate plate then corresponding to the dimensions of the carrier plate (20).

8. Method according to one of claims 1 to 4, wherein the decoration is applied to the carrier plate (20) as a direct print.

9. Method according to one of claims 1 to 8, wherein the carrier plate (20) has a carrier plate length (LT) in the range of 2.6 to 5.8 m.

10. Method according to one of claims 1 to 9, wherein the carrier plate (20) has a carrier plate width of 1.8 to 2.5 m.

11. Method according to one of claims 1 to 10, wherein the decorative image width corresponds to the carrier plate width.

12. A plurality of decorated panels (24) for furniture or doors, wherein the decor reproduces a natural surface, - with carrier panels (20) with a carrier panel length (LT) and - with a surface layer connected to the carrier panels (20) with a decor, wherein the decor is repeated after a decor image length (LD) according to a repeat, characterized by - thatthe decorative image length (LD) in units of the carrier plate length (LT) in one of the intervals [(n* 0.5+x)*LT; ((n+1)*0.5-y)*LT ] lies with n from the interval [0 ... 5] and x, y greater than 0.05 and less than 0.

3.

13. A plurality of decorated plates (24) having the features of one or more of claims 2 to 11.

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