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 their substrate, coated with one or more layers of paper, paint, or lacquer. Specifically, a printed decorative paper is used to create a design on one of the two top surfaces, which may be further coated with at least one additional overlay layer to increase abrasion resistance. Alternatively, a design can be printed directly onto the substrate instead of decorative paper.

[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 plastic mixture, or a natural material such as cork can be decorated.

[0004] The size of the tiles of the type primarily relevant here is in the range of dimensions exceeding 1.4 meters. For example, the tiles are manufactured in lengths of 5.6 m and widths of 2.08 m and then divided into tiles approximately 2.8 m long. These tiles are also referred to as half-formats, which, after production, are separated into smaller tile sections of standard sizes. The general aim is for the half-format to feature a design that creates a visually varied appearance, both as a whole and when divided into smaller tile sections.

[0005] For maximum visual variety, the repeat pattern of the decorative print is a crucial factor. Repeat printing involves a continuously recurring print image without visible breaks. This method is used for continuous print images, such as decorative printing.

[0006] A repeat is a pattern that is constantly repeated during continuous printing, and the entire design is created through this repetition. A repeat is characterized by its length and 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 substrate panel length of 5.6 m 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 divided in the same way and smaller panel sections are produced, the resulting panel sections from a single half-format will have an identical appearance. If the panel sections are joined to form a larger surface, the repeating pattern of the individual panel sections can be noticeable when viewing the finished component, such as a piece of furniture or a door.

[0008] From EP 4 215 383 A1 it is known to select the repeat length or the decorative length to be greater than twice the length of the carrier plate, which is also referred to as the core of the decorative component to be manufactured. While this achieves a greater variety of decorative elements, identical plate sections still always occur after cutting.

[0009] EP 1 908 608 A1 discloses a method for manufacturing decorative components where 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. Here, too, the application lies particularly in smaller component dimensions of the half-formats.

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

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

[0012] Therefore, the present invention is based on the objective of achieving a larger number of differently decorated half-formats and thus also of differently decorated plate parts after dividing decorated half-formats.

[0013] The aforementioned problem is solved according to the invention by a method for producing decorated panels, in particular wood-based panels, in which substrate panels with a substrate panel length (LT) are provided and in which each substrate panel is provided with a decoration, the decoration repeating according to a pattern repeat after a pattern length (LD). The method is characterized in that the pattern length (LD), in units of the substrate 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 the 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] By avoiding integer multiples of 0.5, each with a range defined by x and y, the invention results in a sufficiently large offset of the decorations between each pair of consecutive decorations during the production of the decorated panels. This means that the decorated panels, as half-formats, and consequently the panels themselves after being cut into individual parts, differ significantly more often and to a much greater extent in their decorations than if the integer multiples of 0.5 were included. Therefore, the advantage is achieved that a larger number of panels with different appearances can 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 arbitrarily combined panel parts 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 finish. However, the decoration can also be a reproduction of a stone surface.

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

[0019] For example, the substrate panels onto which the decoration is applied can have a substrate panel length on the order of 5.6 m. Immediately following the application of the decoration by pressing a decorative paper, the coated panels are halved, so that the resulting panel sections, also called half-format panels, have a length of 2.8 m. In this way, panels (half-formats) with a decoration image length greater than 2.8 m are produced. If n now has a value from the interval [1 ... 5], the decoration image length is greater than the half-format panel length, and no repetitions of specific image sections occur on a decorative half-format panel. In addition, the subsequently divided smaller panel sections, as components, all have different image sections.

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

[0021] The core board material 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-plastic composite, or a natural material such as cork. The core board can also preferably consist of laminated panels, compact panels, or several layers of core paper pressed together.

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

[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 which correspond to the dimensions of the substrate, and the decorative paper layer and the substrate, as well as optionally further layers, are pressed together under pressure and temperature to form a decorated sheet. Further layers may include overlay papers, backing papers, core papers (kraft papers), or one or more varnish layers applied before or after pressing.

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

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

[0026] Similarly, in the production of laminate or compact panels, the decorative layer can be pressed together with the underlying layers in a single process. In this case, the top layer of the laminate or compact panel is the decorative layer, and the underlying layers constitute the core board.

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

[0028] It is also possible to apply the decoration to the substrate as a direct print, especially using digital printing or gravure printing processes.

[0029] Furthermore, the substrate can have a substrate length (LT) ranging from 2.6 to 5.8 m and / or a substrate width of 1.8 to 2.5 m. This determines the format that must be considered with regard to the pattern repeat length. According to the described intervals for the permissible decorative pattern lengths in units of the substrate lengths, the pattern repeat length must be chosen to be relatively long.

[0030] Furthermore, the decorative image width preferably corresponds to the substrate width. This prevents any repetition in the direction of the decorative width.

[0031] The problem described above is also solved 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 bearing a decoration, wherein the decoration repeats according to a pattern repeat after a pattern length (LD). The plurality of decorated panels is characterized in that the pattern 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 majority of decorated plates are formed with one or more of the features described above for the process.

[0033] The invention will now be explained using exemplary embodiments with reference to the drawing. The drawing shows... Fig. 1 a printing device for printing a decorative paper web with a repeating decor and Fig. 2a-c a schematic representation of the different divisions of the decor image lengths and carrier plate lengths.

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

[0035] The decoration 12 produced by the printing device 2 has a decoration image length LD, such that the decoration pattern repeats at the end of each decoration image length LD. This pattern is shown here as an example and for clarification, representing a reproduction of a natural wood grain pattern. To better illustrate this, the transition from the end of the decoration after decoration length LD to the next beginning of the repeating decoration is shown with an interruption in the grain. This further clarifies the decoration length LD, in addition to the dashed line between two identical decoration sections. However, in the production of decorated panels, a decoration is generally used that transitions seamlessly at the end into the repetition of the decoration at the beginning.

[0036] Fig. 2a Figure 24 shows a prior art plurality of decorative panels 24, in which a substrate panel 20 with a substrate panel length LT is coated with a decor with a decor image length LD, where the decor image length LD is chosen to be equal to the substrate 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 is produced. When the decorated panels 24 are used further, the decor is repeated in the same locations, which influences the visual impression. Because the design is often repeated in the same locations, a natural appearance is diminished, since panels made from natural materials do not exhibit such a repetition effect.

[0037] The Fig. 2b und 2c Figure 24 shows a plurality of decorated plates 24 as obtained by applying the method according to the invention. Carrier plates 20 with a carrier plate length LT are provided, and each carrier plate 20 is provided with a decoration, the decoration being repeated after a decoration image length LD according to a repeat.

[0038] In general terms, 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] If, for example, LD = 1.11 * LT, then the identical decor will only very rarely be repeated on the carrier plates, resulting in a very large set of differently decorated carrier plates.

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

[0041] Fig. 2c Figure 3 shows a plurality of decorated plates 24, where LD = 0.9 * LT. The decoration is therefore repeated only every eleventh decorated plate 24, which lies outside the area shown in Figure 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. Method for producing decorated boards (24) for furniture or doors, the decor reproducing a natural surface, - in which substrate boards (20) having a substrate board length (LT) are provided, and - in which, in each case, a substrate board (20) is provided with a decor, wherein the decor recurs after a decor image length (LD) according to a rapport, characterized - in that the decor image length (LD), in units of the substrate board length (LT), falls 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 larger than 0.05 and smaller than 0.3.

2. Method according to claim 1, - in which the decor image length (LD), in units of the substrate board length (LT), falls in one of the intervals [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. Method according to claim 1 or 2, in which n has a value from the interval [1 ... 5].

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

5. Method according to any one of claims 1 to 4, - in which a paper web (4) is printed with a decor, - 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 substrate board (20), - in which the decorative paper layer and the substrate board (20), and optionally further layers, are pressed together under the action of pressure and temperature to form a decorated board (24).

6. Method according to any one of claims 1 to 4, - in which a paper web (4) is printed with a decor, - in which the printed paper web (8), together with a plurality of resin-impregnated paper layers, is pressed in a throughfeed press under the application of pressure and temperature to form a decorative laminate, - in which the decorative laminate is cut into individual boards after pressing, the dimensions of the laminate board corresponding to the dimensions of the substrate board (20), and - in which the substrate board (20) is coated with the decorative laminate board.

7. Method according to any one of claims 1 to 4, - in which a paper web (4) is printed with a decor, - in which the printed paper web (8), together with a plurality of resin-impregnated paper layers, is pressed in a throughfeed press under the application of pressure and temperature to form a decorative laminate, - in which adjacent substrate boards (20) are coated with the continuous decorative laminate board, in particular with a decorative laminate board unwound from a roll, and - in which the decorative laminate is cut after pressing in accordance with the subdivision of the substrate boards (20), the dimensions of the respective laminate board then corresponding to the dimensions of the substrate board (20).

8. Method according to any one of claims 1 to 4, in which the decor is applied to the substrate board (20) as a direct print.

9. Method according to any one of claims 1 to 8, in which the substrate board (20) has a substrate board length (LT) in the range from 2.6 to 5.8 m.

10. Method according to any one of claims 1 to 9, in which the substrate board (20) has a substrate board width from 1.8 to 2.5 m.

11. Method according to any one of claims 1 to 10, in which the decor image width corresponds to the substrate board width.

12. Plurality of decorated boards (24) for furniture or doors, the decor reproducing a natural surface, - with substrate boards (20) having a substrate board length (LT), and - with a surface layer connected to the substrate boards (20) and having a decor, the decor recurring after a decor image length (LD) according to a rapport, characterized - in that the decor image length (LD), in units of the substrate board length (LT), falls 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 larger than 0.05 and smaller than 0.3.

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