System for manufacturing a substrate with a decorative design - Patents.com

Abstract

To provide a system for manufacturing, in a versatile manner, a substrate having a decorative design, such as an image and / or a relief.SOLUTION: The system comprises feed means 10 for feeding a foil 2, digital printing means 5, 40 for printing the decorative design 3 on the foil 2, and coating means 30 for coating the substrate 1 with the foil 2. The system is configured for printing the foil 2 with the digital printing device 5, 40 after supplying the foil 2 with the feed means 10 before coating the substrate 1 with the coating means 30.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a system for producing substrates, such as panels or profiles, incorporating decorative designs, such as images and / or reliefs, as a surface finish that matches the identity of the substrate.

[0002] The invention particularly relates to the coating of substrates with flake or layer material, and is particularly applicable to construction and furnishing products such as furniture, panels for doors and floors, profiles for door and window frames, etc. [Background technology]

[0003] Currently, systems are known for applying a decorative design formed by an image and / or a relief placed on the surface of a foil covering a substrate, in which the foil has a decorative design incorporated therein, and then a panel or profile is covered with the foil and they are bonded together by an adhesive applied between the foil and the substrate.

[0004] Today's demands increasingly require continuous production of substrates with slightly repeating decorative designs, which forces the changing of the foil supply or continuous foil supply spools to replace the printed foil with each required decorative design to obtain a variety of decorative designs produced by one and the same system. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention aims to provide a system for producing substrates with decorative designs, which makes it possible to obtain substrates with a wide variety of decorative designs in a versatile manner. [Means for solving the problem]

[0006] To achieve the above mentioned objects, and to provide additional advantages as described below, the present invention provides a system for producing a substrate with a decorative design, such as an image and / or a relief, comprising a supplying means for supplying a flake, a digital printing means, in particular an inkjet printing means, for a decorative design on the surface of the flake, and a coating means for coating the substrate with the flake.

[0007] According to the invention, the system is configured to print the flakes with a digital printing device after the supplying means has supplied them and before the coating means has coated the substrate. By incorporating a digital printing means into the system, substrates with different decorative designs can be obtained in a versatile manner, making it possible to select the printing required for each flake coating the respective substrate.

[0008] In this way, any desired appearance can be imparted to the substrate, and the decorative design can even be changed without the need to change the supply spool or foil. Similarly, various surfaces of the substrate (top, side edges, bottom (fully or partially), etc., even complex surfaces) can be coated with different decorative designs for different selected surface areas.

[0009] This ability to apply different decorative designs to one and the same flake allows for greater flexibility in the application of the coating, for example, allowing the flakes to have different decorative designs on different sides of the substrate, particularly the top and edges of the panel, or to provide continuity in the decorative design between different sides.

[0010] The supply means for supplying the flakes according to the invention can be arranged to supply the flakes continuously, for example by a flake supply spool, or alternatively the supply means for supplying the flakes can be arranged to supply the flakes discontinuously, for example by means of a means for supplying each flake.

[0011] It is conceivable that the system according to the invention comprises a processing unit functionally connected to the digital printing means, whereby the processing unit is configured to print different decorative designs for different substrates and / or flakes. Preferably, the processing unit can be configured to print different decorative designs depending on the physical characteristics of the substrate and / or flake, e.g. size, shape, material, surface roughness, etc. Thereby, it becomes possible to provide different substrates with different decorative designs in a flexible manner and in real time.

[0012] According to the present invention, it is contemplated that the physical characteristics of the substrate and / or flake may be detected, for example, by scanning or detecting the substrate and / or flake or by instructions received by a processing unit. To this end, the system may incorporate a scanner or sensor, for example, to directly detect the physical characteristics of the substrate and / or flake or to detect markings or identifications on the substrate and / or flake.

[0013] The system according to the invention may further comprise an application means for applying adhesive to the substrate and / or the flakes, whereby the substrate and / or the flakes are bonded together by the adhesive after coating. The application means for applying the adhesive may be for example by lip, roller, spray, digital print, especially inkjet, etc.

[0014] Alternatively or additionally, it is also contemplated that the foil may be supplied at least partially pre-adhesive.

[0015] Preferably, the treatment unit is functionally connected to application means for applying adhesive and is envisaged to be configured to apply different amounts of adhesive depending on the physical characteristics of the substrate and / or flake, e.g. size, shape, material, surface roughness, etc. Hereby it is possible to obtain a more flexible production of substrates with decorative designs depending on the different physical characteristics of the substrate and / or flake and thus of the decorative design.

[0016] According to the invention, the coating means may be configured to mold the flakes on the surface of the substrate, so as to conform the flakes to the shape of the substrate.

[0017] The invention further envisages that the system according to the invention comprises a first digital printing means for the image and a second digital printing means for the relief, the system being arranged such that the first and second means print the image and the relief respectively in synchronism with each other, whereby a relief corresponding to the image can be obtained, imitating or reproducing, for example, a textured or tactile surface of a natural material such as wood or stone. [Brief description of the drawings]

[0018] The following figures are included as part of the description of at least one embodiment of the present invention. [Figure 1] 1 shows a schematic diagram of a first embodiment of a system according to the invention; [Diagram 2] 2 shows a schematic diagram of a second embodiment of a system according to the invention, which, unlike the first embodiment, coating the substrate with flakes comprises molding the flakes. [Diagram 3] FIG. 2 shows a schematic diagram of a first variant of a first embodiment of a system according to the invention, in which the application of adhesive is performed by digital inkjet printing instead of a lip. [Figure 4] 3 shows a schematic diagram of a second variant of the first embodiment of the system according to the invention, in which the application of adhesive is carried out by a roller instead of a lip. [Diagram 5] 3 shows a schematic diagram of a third embodiment of a system according to the invention, which differs from the first embodiment in that the adhesive is applied to both the foil and the substrate. [Figure 6] 3 shows a schematic diagram of a first variant of the third embodiment of the system according to the invention, in which the application of adhesive to the foil is performed by a lip instead of by digital inkjet printing. [Figure 7]FIG. 1 shows a schematic diagram of a second variant of the third embodiment of the system according to the present invention, in which the application of adhesive to the thin flakes is performed by a lip instead of digital inkjet printing and the application of adhesive to the substrate is performed by a roller instead of digital inkjet printing and. [Figure 8] 4 shows a schematic diagram of a fourth embodiment of a system according to the invention, which differs from the previous embodiments in that the supply of slices is discontinuous, i.e. slice by slice, instead of a spool of continuous supply. [Figure 9] 1 shows a schematic diagram of successive steps in an exemplary embodiment of a process for manufacturing a substrate with a decorative design, which can be carried out with a system according to the invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The system of the invention uses a substrate (1) as a base product, which is coated with a foil (2) on which an individual decorative design is applied "in situ" in a continuous manner using digital inkjet printing means (5, 40). This results in a substrate (1) coated with a printed foil (2) with a surface finish with a decorative design (3). Thereby, any desired appearance can be given to the substrate (1), e.g. a panel or a profile, depending on the decorative design (3) of the coating foil used.

[0020] The substrate (1) can be made of various materials, for example wood derivatives (chipboard, medium density fiberboard "MDF", high density fiberboard "HDF" or plywood), plastic materials (PVC), cellulosic materials (paper or cardboard), metal materials, etc. The flakes (2) can be made of, for example, paper, PVC, HPL, CPL, etc.

[0021] The digital inkjet printing means (5, 40) comprises at least one digital inkjet printhead (5) and digital print curing or drying means (40) for curing and / or drying the printing inks which produce the decorative design.

[0022] The supply means (10; 90) for supplying the flakes (2) can be continuous (10) or discontinuous (90). In the embodiment of figures 1 to 7, the flakes (2) are supplied continuously on a supply spool (10) and guided towards coating of the substrate (1) by at least one guide roller (20, 60). In the embodiment of figure 8, the flakes (2) are supplied discontinuously, i.e. flake by flake, from a stack of flakes (90).

[0023] To apply the adhesive (4), it is conceivable that the system comprises application means (6; 7, 70; 8, 9; 11, 80; 12, 13) for applying the adhesive, configured to apply the adhesive (4) to the substrate (1) and / or the foils (2) that will be glued together after coating. The application of the adhesive (4) can take place before or after the digital printing. In the variant of the system shown in the figures, the application of the adhesive (4) takes place after the application of the decorative design (3). However, it is also conceivable according to the invention that it can take place alternatively or supplementarily before the application of the decorative design.

[0024] The covering means (30; 50, 51) of the substrate (1) with the flakes (2) comprises a pressure roller (30) for spreading the flakes (2) on the surface of the substrate (1), so that the flakes (2) cover the surface of the substrate (1), in particular the flat surface. In the embodiment of FIG. 2, the covering means (30; 50, 51) further comprises a forming roller train (50, 51) for forming the flakes (2) on the substrate (1) surface, in this case folding the flakes (2) over the side edges of the substrate (1), but can be configured so that the flakes (2) cover surfaces of the substrate (1) that are inclined relative to one another or complex surfaces. By applying pressure with the covering means (30; 50, 51), the bond between the substrate (1) and the flakes (2) is made.

[0025] As shown in FIG. 1, a continuous flake (2) is fed from a supply spool (10) by guide rollers (20) and a decorative design (3) is applied to the surface of the flake (2) by a digital inkjet print head (5), followed by curing or drying by a digital print curing or drying means (40).

[0026] The adhesive (4) is applied to the foil (2) carrying the decorative design (3) by means of an adhesive application lip (6) and once the adhesive (4) has been applied, the already adhesive printed foil (2) is applied to the substrate (1) and the substrate (1) is covered by pressing the foil (2) against the substrate (1) using a pressure roller (30) to obtain a perfectly uniform final product.

[0027] As can be seen in the other figures, there are many variations depending on the components used in the system and their arrangement, so it is not limited to the embodiment shown in FIG.

[0028] Thus, in the schematic embodiment of Fig. 2, the above is followed by a shaping step by forming roller trains (50, 51). The flakes (2) thus conform to the shape of the substrate (1) and cover it, so that both the front surface and the edges are covered by the flakes (2).

[0029] The forming roller train (50, 51) consists of a longitudinal row of pressure means (usually wheels with different characteristics) for shaping, post-shaping or profiling the flakes (2) on the surface of the substrate (1) in the direction of travel of the substrate to be coated. Other strategically arranged components can be used to bond the flakes (2) to the substrate and to adapt them to the shape of the substrate (1) until the final shape of the flakes (2) integrated with the substrate (1) is obtained at the end of the process.

[0030] Similarly, in the embodiment of Fig. 3, after digital inkjet printing, adhesive (4) is applied to the thin flake (2) after it has been guided by two successive thin flake guide rollers (20 and 60). In this variant, application of adhesive (4) is performed by an adhesive digital inkjet printhead (7) and subsequent curing or drying in adhesive curing or drying means (70) before application of a rotating pressure roller (30) in the direction of advancement of the substrate (1).

[0031] Additionally, the embodiment of FIG. 4 follows the same process, but the adhesive (4) is applied to the foil (2) by an application roller (8) cooperating with an adhesive addition roller (9) which adds a predetermined amount of adhesive (4) to the application roller (8) by relative rotation and movement between the application roller (8) and the adhesive addition roller (9).

[0032] Similarly, in the embodiment of the system shown in figures 5 to 7, the step of digital printing of the decorative design (3) by the digital inkjet printhead (5) is followed by curing or drying in a digital printing curing or drying means (40). The adhesive (4) is applied to the flake (2) and / or to the substrate (1) by a variant on the application of the adhesive (4). Thus, in figure 5, the adhesive (4) is applied to the flake (2) by the digital inkjet printhead (7) and to the substrate (1) by the digital inkjet printhead (11). In both cases, a subsequent curing in an adhesive curing or drying means (70; 80) follows before applying the pressure roller (30).

[0033] Unlike Figure 5, in Figure 6 the adhesive (4) is applied to the foil (2) by a lip (6) and is not subsequently cured. Once the adhesive (4) has been applied, it is pressed against the substrate (1) by a pressure roller (30). The embodiment shown in Figure 7 further differs from that of Figure 6 in that the adhesive (4) is applied to the substrate (1) by an application roller (12) cooperating with an application roller (13).

[0034] FIG. 8 shows how the feed material, i.e. flakes (2), are dispensed discontinuously from a stack of flakes (90) and the application of adhesive (4) is applied only to the substrate (1) by a digital inkjet printhead (7), followed by curing in an adhesive curing or drying means (70).

[0035] The adhesive curing or drying means (40) or digital printing means (70, 80) can be, for example, using electromagnetic radiation, UV, IR or electron lamps, or by hot air drying.

[0036] According to the invention, the system may also include auxiliary means for preparing the substrate (1) and / or the flakes (2), such as, for example, means for priming the substrate (1) and / or the flakes (2), auxiliary means for a protective layer for the flakes (2), auxiliary means for a base layer for creating a relief on the flakes (2) surface, means for removing material from the mixture of droplets ejected by the inkjet for creating a relief on the flakes (2) surface, etc. Figure 9 shows the following steps in a process that can be performed using the system according to the invention: a) Apply primer to the flakes. b) Allow the primer to cure. c) Decorative designs are applied by inkjet. d) Cure or semi-cure the print. e) Applying a protective layer to the printed layer. f) The protective layer is cured or semi-cured. g) Applying a base layer of liquid material in which the embossing will be performed. h) ejecting inkjet droplets of material for mixing with the layer of liquid material; i) Hardening process for the mixture and remaining materials. j) Removing the mixed material by mechanical means. k) Applying a layer of finishing material. l) Allow the finish layer to harden.

[0037] It is also possible to use a substrate (1) and / or foil (2) that has already been previously prepared to receive the decorative design (3) and / or adhesive (4), for example, but not necessarily, by application of a primer layer, or it is also possible to use a foil (2) that is pre-applied with adhesive, in which case no adhesive (4) is applied to the foil (2) during the process.

[0038] The system of the present invention advantageously allows for the reproduction of different decorative designs on the surface of the foil (2) covering the substrate (1) in a continuous process or without the need to change spools (10) or sheets (90). [Explanation of symbols]

[0039] 1 Base material 2 flakes 3. Decorative Design 4. Glue 5. Digital Inkjet Printing Methods 6 Adhesive application lip (application means) 7 Adhesive digital inkjet print head (application means) 8 Application roller (application means) 9 Adhesive application roller (applying means) 10 Supply spool (supply means) 11 Digital Inkjet Printhead 12 Application roller (application means) 13 Additive roller (coating means) 20 Guide roller 30 Pressure roller (covering means) 40 Digital printing curing or drying means (digital inkjet printing means) 50 Forming roller train (covering means) 51 Forming roller train (covering means) 60 Guide roller 70 Adhesive hardening or drying means (coating means) 80 Adhesive hardening or drying means (coating means) 90 Stack of slices (supply means)

Claims

1. A system for producing a substrate (1) with a decorative design (3), such as an image and / or a relief, comprising: - supply means (10; 90) for supplying the flakes (2), - digital printing means (5, 40) for printing said decorative design (3) on said foil (2); - coating means (30; 50, 51) for coating said substrate (1) with said flakes (2); a system for manufacturing a substrate (1) with an ornamental design (3), the system being configured to print the flakes (2) with the digital printing means (5, 40) after supplying the flakes (2) with the supplying means (10; 90) and before coating the substrate (1) with the coating means (30; 50, 51), the system comprising a processing unit operatively connected to the digital printing means (5, 40), the processing unit being configured to print different decorative designs (3) on the flakes (2) for different substrates (1) and flakes (2) depending on physical characteristics of the substrate (1) and the flakes (2), such that various selected surface areas of the substrate (1), such as the top surface, the side edges, the bottom surface or a complex surface of the substrate (1) can be coated with the flakes (2) with different decorative designs (3) or to provide continuity for the decorative design (3) between different surfaces of the substrate (1).

2. 2. A system for manufacturing a substrate (1) with a decorative design (3) according to claim 1, characterized in that it comprises application means (6; 7, 70; 8, 9; 11, 80; 12, 13) for applying adhesive (4) to the substrate (1) and / or the foil (2), whereby the substrate (1) and / or the foil (2) are bonded together by means of said adhesive (4) after coating.

3. 3. A system for manufacturing a substrate (1) with a decorative design (3) according to claim 2, characterized in that the processing unit is functionally connected to the application means (6; 7, 70; 8, 9; 11, 80; 12, 13) for applying adhesive, the processing unit being configured to apply different amounts of adhesive (4) depending on the physical characteristics of the substrate (1) and / or the foil (2).

4. 4. A system for manufacturing a substrate (1) with a decorative design (3) according to claim 2 or 3, characterized in that the coating means (30; 50, 51) are configured to mold the flakes (2) on the surface of the substrate (1) so as to adapt the flakes (2) to the shape of the substrate (1).

5. 5. A system for manufacturing a substrate (1) provided with an ornamental design (3) according to any one of claims 1 to 4, characterized in that the digital printing means (5, 40) of the ornamental design (3) comprises a first digital printing means for an image and a second digital printing means for an engraving, the system being configured such that the first digital printing means and the second digital printing means print the image and the engraving, respectively, in synchronism with each other.

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