METHOD FOR MANUFACTURING A DECORATIVE PANEL THAT HAS IMPROVED SYNCHRONICITY BETWEEN DECORATION AND STRUCTURE

Abstract

The present invention relates to a method for producing a structured decorative panel (44), comprising the following method steps: a) providing a film (14) to be structured; b) providing a stamping means (18) for structuring the film (14); c) structuring the film (14) using the stamping means (18) so as to form at least one structured region (20) on the film (14); d) determining at least one dimension of at least one structured region (20) after step c); e) providing a substrate (36); f) applying a decoration to the substrate (36); wherein, g) the at least one dimension of the structured region (20) determined in step c) is taken into account during the application of a decoration to the substrate (36); and h) applying the film (14) to the substrate (36) such that the at least one structured region (20) is synchronized with the decoration.

Description

[0001] The present invention relates to a method for producing a structured decorative panel, in particular by structuring synchronously with a decorative element. The present invention further relates to a system with which such a method can be carried out.

[0002] To protect a decorative layer applied to a substrate, wear-resistant or cover layers are usually applied above the decorative layer. Often, such wear-resistant or cover layers incorporate a surface texture that mimics a decorative template, so that the surface of the decorative panel has a tactile structure whose shape and pattern are adapted to the applied decoration, thus achieving the most faithful reproduction of a natural material, including its haptic quality.

[0003] For example, the structure is applied in a known manner using embossing tools. Such a process, in which a structure is created by pressing it into a particularly smooth surface, is referred to as negative structuring in the context of the present invention.

[0004] There is potential for improvement in such processes, as with other structuring processes, such as structuring lacquer application processes, in achieving synchronization between structure and decoration. In negative structuring, for example, the precise alignment of the embossing tools relative to the decoration can potentially cause problems. Therefore, the production of structured surfaces for wear protection may still offer potential for improvement.

[0005] It is therefore the object of the present invention to provide improved means for structured surfaces, for example for wear protection, which at least partially overcome the problems known from the prior art.

[0006] This object is achieved by a method according to claim 1 and further by a system according to claim 15. Preferred embodiments of the invention are specified in the subclaims or in the description, wherein further features described or shown in the subclaims or in the description can individually or in any combination constitute an object of the invention, unless the context clearly indicates the opposite.

[0007] A method for producing a structured decorative panel is described, comprising the method steps: a) providing a film to be structured; b) providing an embossing means for structuring the film; c) structuring the film with the embossing means to form at least one structural region on the film; d) determining at least one dimension of at least one structural region according to method step c); e) providing a carrier, f) applying a decoration to the carrier, wherein g) when applying a decoration to the carrier, the at least one dimension of the structural region determined in method step c) is taken into account; and h) applying the film to the carrier such that the at least one structural region is synchronized with the decoration.

[0008] Such a process can enable improved application of a film to a substrate during the manufacturing process of a decorative panel. In particular, it can enable improved synchronization between the optical decoration and the haptic structure.

[0009] For the purposes of the invention, the term "decorative panel" refers in particular to wall, ceiling, door, or floor panels that feature a decorative pattern applied to a carrier plate. Decorative panels are used in a variety of ways, both in the interior design of rooms and for the decorative cladding of buildings, for example, in trade fair construction. One of the most common applications for decorative panels is their use as floor coverings or for cladding ceilings, walls, or doors. The decorative panels often feature a pattern and surface texture intended to imitate a natural material.

[0010] To produce the decorative panel, the process first comprises, according to process step a), providing a film to be structured. The film is thus to be provided with a haptically perceptible structure, which is intended to function as a so-called synchronous pore in the produced decorative panel. Furthermore, it may be preferred for the film to cover the decoration applied to the carrier and thus represent a protective and / or wear-resistant layer. For example, the film can form the outermost layer of the produced decorative panel.

[0011] When the film is configured as a protective layer or wear layer, the film can cover the decoration upwards to protect the decoration and the substrate from external influences. In this regard, it can be particularly preferably provided that the film comprises hard materials, preferably in an amount between > 5 wt.% and < 40 wt.%, wherein the hard materials preferably have an average grain diameter between 10 μm and 250 μm. Examples include titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide, zirconium nitride, or mixtures thereof.

[0012] The design of the film is not fundamentally limited and depends in particular on the subsequent use of the film or the composite of film and carrier. The film can preferably be made of a plastic, preferably a thermoplastic.

[0013] According to method step b), the method further comprises providing an embossing means for structuring the film. As indicated above, the embossing means serves to introduce, or more precisely, to press, a structure into the film. For this purpose, the embossing means is in turn provided with a structure which corresponds to the negative of the structure to be pressed in or formed. The structure can be introduced into the embossing means, for example, by engraving and can be based on structural data extracted from an existing digital print file. The digital print file can expediently be used to generate the decoration, as described in more detail below. The digital print data can then be translated into structural data of the embossing means. For example, the structural data is used for an engraving, such as laser engraving.Alternatively, the structural data can also be generated by three-dimensional scanning of a structural template, such as textured real wood. With regard to the embossing means, it can be advantageous for it to comprise an embossing roller or, in other words, for an embossing roller to be used as the embossing means. Such embossing means are characterized by the fact that they are easy to manufacture and are also safe and reliable in operation. However, the present invention also encompasses the embossing means being a circulating belt, i.e. an embossing belt, or even a press plate. Using an embossing belt or a press plate or embossing plate, the exposure time of the embossing means to the film can be extended, which can also be advantageous with regard to structuring. For example, lower pressure can be used.

[0014] Accordingly, the embossing means serves for negative structuring, by means of which, according to process step c), the structuring of the film with the embossing means can take place, forming at least one structural region on the film. Thus, after structuring by the embossing means, the film has one or more structural regions that are intended to correspond to the structure of the decorative panel and that are correspondingly adapted to the decorative data of the produced decorative panel. The structural region(s) can correspond to the surface of the decorative panel to be produced, which is to be provided with a structure. For example, the structural region(s) can correspond to the decorative regions of the decorative panels to be produced.

[0015] According to method step d), at least one measurement of at least one structural region is determined after method step c). According to this method step, at least one measurement of the structural region(s) is determined after the film has been structured. This method step takes place, for example, under ambient conditions, i.e. in particular at ambient temperature or at least after a certain cooling of the film after structuring. For example, this method step can take place at room temperature, i.e. in particular at 22°C or in a range of 22°C with a maximum deviation of + / - 15°C. In principle, however, it can be sufficient for the determination of the at least one measurement to take place after structuring.

[0016] Determining at least one dimension of the structural area can be performed in a manner known per se to those skilled in the art, depending on the specific dimension selected. For example, a two-dimensional dimension, such as the length and / or width, can be determined using camera-based methods or scanner-based methods. In principle, optical scanning of the structural area can be advantageous. Determining the dimension is understood, in a manner understandable to those skilled in the art, to mean equally determining a dimensional change during structuring, or in other words, as a result of structuring, since this allows direct conclusions to be drawn about the dimension.

[0017] According to process step e), a carrier is further provided, and thus in particular a carrier which is to be provided with the film or onto which the film is to be applied.

[0018] The type of carrier is not fundamentally limited, as long as the carrier can serve as a base or substrate for the film. In other words, a carrier can basically be understood as any structure that serves as a substrate for a film to be laminated. In the case of the production of a decorative panel, however, the carrier can be a suitable carrier for this purpose. A carrier can then be understood in particular as a layer serving as the core or base layer in a finished panel, which can in particular comprise a natural material such as a wood-based material, a fiber material or a material comprising a plastic. For example, the carrier can impart suitable stability to a panel or contribute to this. The carrier can in particular be a web-like carrier or plate-shaped carrier.For example, such a carrier can be made of plastic, whereby such a carrier can be made of pure plastic or a plastic material. A plastic material should be a material that, in addition to the pure plastic, can also contain other components, in particular fillers such as mineral or inorganic components.

[0019] Furthermore, according to process step f), a decoration is applied to the carrier. Within the context of the present invention, it is particularly advantageous for the decoration to be printed onto the carrier, in particular by means of a direct printing process.

[0020] The term "direct printing" in the context of the invention refers to the application of a decoration directly onto the substrate of a panel or onto a non-printed or partially printed fiber material layer applied to the substrate. Unlike conventional processes, in which a decorative layer previously printed with a desired decoration is applied to a substrate, with direct printing, the decoration is printed directly during panel production. Various printing techniques can be used, such as flexographic printing, offset printing, or screen printing. Digital printing techniques, such as inkjet or laser printing, can be used in particular.

[0021] In order to enable a particularly precise print image with a particularly high degree of accuracy of the decoration, the carrier can preferably be treated with means for changing the electrostatic charge of the carrier before being fed to the printing unit and / or during the printing process in the printing unit by first electrostatically discharging the carrier and then, if necessary, supplying a defined amount of charge to the carrier.

[0022] According to the invention, it is further provided that, according to method step g), when applying a decoration to the carrier, the at least one dimension of the structural region determined in method step c) is taken into account. Accordingly, the decoration is not necessarily applied, in particular printed, strictly according to predetermined data that are independent of the size of the structural regions, but when applying the decoration, in particular when printing the decoration, the at least one dimension of the structural region or regions is taken into account. In particular, the dimension of the decoration, the dimension of the structural region of which is taken into account, is adapted to the corresponding dimension of the structural region. For example, the length and / or width of the decoration can be adapted to the determined length and / or width of the structural region and the decoration can be printed accordingly.The print data is therefore adjusted before or during the manufacturing process so that the original print data can be used or adjusted accordingly while maintaining exact compliance with the dimensions of the structural area(s).

[0023] In the event that the dimension approximately comprises the length and / or width of the structural area as described below, an adjustment can be made by adjusting the length and / or width of the decoration accordingly. For this purpose, previously determined and stored decoration data which is assigned to specific parameters of the dimension can be used if necessary. In other words, if the dimension assumes a certain value, decoration data previously assigned to the corresponding dimensions can be used to print the decoration. Alternatively, a mathematical correction of the decoration data can be made directly based on the determined dimension or dimensions by adapting the decoration, such as its extension or size, to the dimension or dimensions during the process by creating adapted decoration data which can then be used.

[0024] According to process step h), the film is further applied to the carrier in such a way that the at least one structural region is synchronized with the decoration. Thus, for example, the entire carrier, such as an entire surface of the carrier, can be coated with the film, or the carrier can be coated with the film only partially.

[0025] This can be achieved, for example, by guiding the film to the carrier and then pressing it onto the carrier, for example, using a roller, for example, at a temperature elevated above room temperature (22°C) and a pressure elevated above ambient pressure (1 bar). This process step can also be described as lamination and can, in principle, be carried out in a selectable form. For example, the invention encompasses wet lamination or dry lamination, in which the lamination is carried out using a wet or dry laminating agent.

[0026] If the carrier and film are made of different polymers, adhesive and / or a bonding layer or hotmelt can be used as a laminating agent. Coextruded thermoplastic functional layers that are firmly bonded to the carrier or film during production can also be used as a bonding layer, such as EVA (ethylene-vinyl acetate copolymer) or a grafted MAH (maleic anhydride-grafted polymer). The laminating parameters are then adjusted to these functional layers between the film and carrier. Example parameters for EVA include a temperature of 70°C to 100°C, depending on the vinyl acetate content in the EVA, and a pressure of 1 to 10 bar. During laminating, however, care should be taken to ensure that the temperature and pressure are set sufficiently low so as not to damage the previously embossed structure, which can easily be achieved, for example, using laminating agents.

[0027] After this step, the film can be firmly fixed to the carrier. If necessary, post-treatment, such as drying or curing of the laminating agent or even the film, can be carried out. In the described method, it can further be provided that the film is electrostatically charged before being applied to the carrier and that the carrier is electrostatically charged before the film is applied to the carrier. Electrostatic charging can in principle be carried out as is known from the prior art in other fields, for example by means of ionization devices. In principle, it is preferred that the electrostatic charging of the carrier and the film is carried out in such a way that the film and the carrier are electrostatically charged in opposite directions.For example, the carrier can be negatively charged and the film can be positively charged, or conversely, the carrier can be positively charged and the film can be negatively charged.

[0028] This process step allows for an electrostatic attraction between the carrier and the film. This allows for a particularly close bond, for example, when the carrier is coated with the film over a large area.

[0029] It may further be preferred that at least one of the carrier and the film be electrostatically discharged prior to electrostatic charging. In this embodiment, the aforementioned advantages can be achieved in a particularly reliable and defined manner.

[0030] According to the method according to the invention, and in particular by taking into account, in process step g), at least one dimension of the structural area determined in process step c) when applying a decoration to the carrier, it is possible to achieve particularly precise synchronization of the haptic structure with the decoration. This is because the formation of the structure and the decoration is not carried out exclusively according to predetermined data, but rather an adaptation of the decoration and structure is carried out based on the actual dimensions of the structure. In this case, it can be taken into account in particular that during the introduction of the structure, in particular when the structure is pressed in using pressure and heat, the film can change in its dimensions, so that the ultimately produced structural areas do not necessarily correspond to the area originally intended for structuring.

[0031] The dimensional change can depend on the film material, the film thickness, the specific structure applied, and the embossing conditions, particularly the temperature used during embossing. Other influencing factors include the embossing speed and the tensile behavior of the film during embossing, which is a particularly material parameter. Accordingly, it is not always possible to accurately predict the dimensional change in the film caused by structuring.

[0032] Accordingly, the method according to the invention makes it possible to meet particularly high requirements for the synchronicity of structure and decor, regardless of the conditions used, the specific design of the film and the pressed-in structure, and thus to produce a particularly high-quality decorative panel.

[0033] If the foil is coated with a varnish, such as UV-curable acrylic varnish, before embossing, which then already represents the final surface, there is the further advantage that the final coating of deep structures is less problematic, for example with regard to the appearance of highlights.

[0034] Preferably, the at least one dimension can comprise the length of the structural region. Alternatively or additionally, the at least one dimension can comprise the width of the structural region. In particular, the length and / or the width of the structural region or regions can reliably indicate a dimensional change that, as a whole, is representative of the dimensional change even in small regions of the film, since a dimensional change usually runs uniformly through the structural region. Thus, by adjusting the overall length or the overall width of the decoration, an adjustment can also be correct in the individual structural elements. This embodiment can thus enable a simple adaptation of the decoration to the structure.

[0035] In addition, the length and / or width of the structural areas can be easily determined, for example by optical scanning, which makes the method reliable to implement.

[0036] With regard to the film, it may be preferred that it is made of plastic, for example consists thereof or also comprises further components. More precisely, the film can comprise an acrylate-based plastic composition, in particular a polyurethane-modified acrylate plastic composition, wherein the film can comprise the plastic composition in an at least partially, for example completely, cured form, so that it can be transported and treated accordingly for lamination. Any necessary final curing of the film can optionally take place in a further step following lamination. This can be done, for example, using high-energy and short-wave UV radiation and, in addition to the radical polymerization of the acrylate groups, leads to additional cross-linking of the monomers. This considerably increases the surface hardness. Water-based systems are also possible.

[0037] This advantageously ensures that the film is flexible overall and at the same time has particularly good protective properties such as stability, scratch resistance, heat resistance, water resistance and the like for a wide range of applications, for example as a protective layer of a decorative panel.

[0038] Preferably, the plastic composition of the film may comprise a dipropylene glycol diacrylate, preferably in an amount of > 0 to < 15 wt.% based on the plastic composition, and a reaction product of pentaerythritol, epichlorohydrin and acrylic acid, preferably in an amount of > 2 to < 15 wt.% based on the plastic composition.

[0039] Furthermore, the film can also be made of other, particularly thermoplastic, plastics, such as polyethylene terephthalate (PET) or polypropylene.

[0040] It may further be preferred for the embossing means to have a neutral region in the longitudinal direction adjacent to at least one structure-forming region. A neutral region is understood to mean, in particular, a region that is not provided with a structure adapted to a decoration. Thus, the neutral region does not serve to create a synchronous pore.

[0041] By providing such a neutral zone, it is possible to adjust the distance between two structural areas of the film, particularly in the longitudinal direction of the film, to the distance between two areas of the carrier when the film is laminated. Particularly preferably, adjustment can be made to the distance between two decorative areas, particularly of different carriers. Thus, the film is structured, particularly in the longitudinal direction, only at the positions that are positioned on a decorative area when the carrier and film are brought together.

[0042] This design allows for a clear demarcation between structural and neutral areas, improving and simplifying the positioning of the film on the substrate, thus further improving the synchronization between the decor and the structure. This further reduces the risk of incorrect positioning of the film on the substrate, and thus of the structure on the decor.

[0043] For example, the neutral area can at least partially have a structure that differs from the structure-defining area. In this embodiment, the different structure can facilitate camera-based detection, for example, through a defined structure.

[0044] Alternatively, the neutral range can at least partially encompass a structure-free area. This, too, can be easily distinguished from the structured area, for example, using a camera.

[0045] The distance between two decorative areas of different substrates can, for example, mean the panel spacing in a laminating system, i.e. the distance between two substrates, or even a larger distance, for example if edge joints are not to be provided with a structure.

[0046] Accordingly, it may be preferred that the film is applied in the longitudinal direction to a plurality of supports, wherein the supports each have a surface to be structured, wherein the surfaces to be structured of different supports are spaced apart from one another, and wherein the distance between the surfaces to be structured corresponds to the length of a neutral region.

[0047] Preferably, by maintaining the process parameters, for example, at least for the structuring of a foil batch, such as a foil roll, it should be ensured as best as possible that the structured areas and free areas always have the same length, and furthermore, that the dimensions also remain constant. This can prevent the ratio of decoration to structural areas from changing, thus deteriorating the synchronization of decoration and structure. This can be achieved, for example, by stable temperature and tension control in the embossing system.

[0048] Further preferably, a registration mark can be applied to the decor and the film. A registration mark can be understood as a mark that indicates whether the film is positioned in the desired and planned position on the carrier. If the registration marks are positioned directly above one another, for example, or in a predefined relationship to one another, it can be ensured that the film is correctly positioned, thus meeting high requirements for synchronization between the decor and the structure.

[0049] More preferably, a plastic-containing carrier can be used as the carrier. Particularly preferably, the carrier can comprise a material comprising a plastic and optionally further components. Plastics that can be used in the production of corresponding panels or the carriers are, for example, thermoplastics, such as polyvinyl chloride, polyolefins (e.g. polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or copolymers thereof. The plastics can contain conventional fillers, for example calcium carbonate (chalk), aluminum oxide, silica gel, quartz flour, wood flour, gypsum. They can also be colored in a known manner.The carrier can preferably contain talc as a filler material, for example in an amount, based on the total material of the carrier, of > 30 wt.% to < 70 wt.%, in particular of > 40 wt.% to < 60 wt. Furthermore, the carrier can be multilaminar, i.e., composed of a plurality of films. The films can be the same as or different from the film to be laminated.

[0050] Such plastic carriers are particularly preferred for decorative panels for many applications and can also be easily provided with a film, so that the method can be carried out without problems, especially in this embodiment. It can also be preferred that process parameters and dimensional change data of a film, i.e. data relating to a dimensional change of the film during structuring, are stored and compared with process parameters and dimensional change data of the film or another film during structuring at a later time. In this embodiment, a logic test can therefore be carried out, since at least a rough prediction is possible as to the area in which a dimensional change is sensible or to be expected. This can, for example, reduce incorrect measurements or detect errors in the structuring.The stored and compared data can, for example, include the dimensional change itself and the process parameters such as the pressing pressure, the pressing temperature, the material of the film and / or the thickness of the film.

[0051] The method for producing a decorative panel preferably comprises the further method step: i) introducing locking means at edges of the carrier.

[0052] To create a decorative panel, locking elements are provided along the edges of the support, for example, all the way around. This can be achieved, for example, by machining the support edges, as is generally known from the prior art. This allows a stable composite to be created from a large number of panels, also in a known manner, as a floor covering, ceiling covering, or wall covering.

[0053] For further technical features and advantages of the method, reference is made to the description of the system, the figures and the description of the figures.

[0054] Also described is a system for producing a decorative panel, comprising: an embossing means for structuring a film to be structured, forming at least one structural region on the film; a dimensioning means for determining at least one dimension of at least one structural region after embossing of the film; a decorating means for applying a decoration to a carrier, wherein the at least one dimension of the structural region can be taken into account when applying the decoration to the carrier; and a merging means for applying the film to the carrier such that the at least one structural region is present in synchronism with the decoration.

[0055] The system described here is used in particular to carry out a method as described in detail above.

[0056] For this purpose, the system comprises an embossing means for structuring a film to be structured, forming at least one structural region on the film. The embossing means can be configured as described above and can comprise, for example, an embossing roller or an embossing belt or an embossing plate or press plate.

[0057] The system further comprises a dimensioning device for determining at least one dimension of at least one structural area after embossing the film. The dimensioning device is expediently arranged downstream of the embossing device with respect to the direction of travel of the film. For example, the dimensioning device comprises a camera or a scanner that optically scans the structured film and thus determines the size of the structured area. The dimensioning device can be an analog or digital dimensioning device.

[0058] The further included decorative means for applying a decoration to the carrier can, in particular, be a direct printing device, such as a digital printer. The control of the digital printer can, for example, be connected to the dimensioning means or a control unit thereof via a data connection. This allows a specific dimension of the structured area of ​​the film to be taken into account when applying the decoration. Alternatively, the dimension of the structured area can be entered manually into the decorative means, for example.

[0059] Finally, a joining device for applying the film to the carrier is included in such a way that the at least one structural area is synchronized with the decoration. The joining device can be designed, for example, as a laminating system and, through appropriate control, ensure that the carrier and the film, and thus the decoration and the structure, are placed on top of one another synchronously.

[0060] Such a system can, in particular, improve the synchronicity of a decor with a structure and thus enable a decorative panel of particularly high quality.

[0061] For further technical features and advantages of the method, reference is made to the description of the system, the figures and the description of the figures.

[0062] The invention is explained below by way of example with reference to the attached drawings, wherein the features shown below can represent an aspect of the invention both individually and in combination, and wherein the invention is not limited to the following drawing, the following description and the following embodiment.

[0063] Fig. 1 shows schematically a system for producing a decorative panel;

[0064] Fig. 2 shows an embossing roller for a system according to Fig. 1;

[0065] Fig. 3 shows a foil structured with the embossing roller from Fig. 2 in a first embodiment; and

[0066] Fig. 4 shows a film structured with the embossing roller from Fig. 2 in a further embodiment. Figure 1 shows a system 10 for producing a decorative panel. The system 10 comprises a feed unit 12 for a film 14 to be structured. The feed unit 12, which according to Figure 1 is a roll 16 with rolled-up film 14, can feed the film 14 to an embossing means 18 for structuring the film 14 to form at least one structured area 20 on the film 14. According to Figure 1, the embossing means 18 is an embossing roller or an embossing cylinder 22, which can structure the film 14 by the film 14 passing through a gap defined by the embossing cylinder 22 and a counter-roller 24.

[0067] The embossing cylinder 22, which can be rotated about an axis 30, is shown by way of example in Figure 2. It can be seen that the embossing cylinder 22 has, on its outer circumference, a structure-forming region 26 and a neutral region 28 having a length h. Engraved into the structure-forming region 26 is, for example, a structure which was digitally extracted from decorative data and can be the negative of the structure to be introduced into the film 14. The neutral region 28 can, in particular, be free of a structure and have a smooth surface, or have a structure different from the structure-forming region 26.

[0068] Returning to Figure 1, a dimensioning means 32 is also shown for determining at least one dimension of at least one structural region 20 after embossing the film 14. As can be seen from Figure 1, the dimensioning means 32 is in particular an optical dimensioning means 32, such as a camera, which optically scans the structured film 14 and thus detects the desired dimension, such as in particular the length or width, of the structural region 20. In principle, however, an analog dimensioning means can also be used and / or dimensioning can take place using a registration mark 48. Furthermore, a feed device 34 for a plurality of plate-shaped carriers 36 is shown, wherein the feed device 34 is designed as a conveyor belt. The feed device 34 guides the carriers 36 to a decorating means 38, which serves to apply a decoration to the carriers 36.In Figure 1, the decoration means 38 is configured as a digital printer, which may have a suitable number of print heads. The decoration means 38, for example a control unit thereof, is connected to the dimensioning means 32 via a wireless data connection 40, for example, in the case where the dimensioning means 32 operates digitally. This makes it possible to take into account at least one dimension of the structural area 20 when applying the decoration to the carrier 36. The simple adaptation of the digital print file allows for fine-tuning of the synchronization of the printing on the structure.

[0069] Finally, the film 14 and the carriers 36 run to a joining station 42 for applying the film 14 to the carrier 36 such that the at least one structural region 20 is synchronized with the decoration. The joining station 42, which is shown only schematically in Figure 1, can be designed in particular as a laminating system. After the joining station 42 or the laminating system, a decorative panel 44 can be produced in which the carrier 36 is provided with a decoration and a structured film 14, wherein the structured film 14 is synchronized with the decoration.

[0070] Accordingly, a method for producing a structured decorative panel 44 can be carried out by the system 10 shown in Figure 1, comprising the method steps: a) providing a film 14 to be structured; b) providing an embossing means 18 for structuring the film 14; c) structuring the film 14 with the embossing means 18 to form at least one structural area 20 on the film 14; d) determining at least one dimension of at least one structural area 20 according to

[0071] Method step c); e) providing a carrier 36, f) applying a decoration to the carrier 36, wherein g) when applying a decoration to the carrier 36, the at least one dimension of the structural region 20 determined in method step c) is taken into account; and h) applying the film 14 to the carrier 36 such that the at least one structural region 20 is present in synchronism with the decoration.

[0072] In principle, the system 10 can be designed as a coherent system 10 in which the steps are carried out contiguously. In this case, the processes continue at the positions of the arrows 50 without interruption. However, it is also possible to interrupt the individual process strands and thus initially store the structured film 14, for example, before or, as shown in Figure 1 by the arrow 50, after the dimensioning means 32. Accordingly, the printed carrier 16 can be stored before passing through the assembly 42 or the laminating system, as is also intended to be shown by the arrow 50. Accordingly, the structured film 14 can be laminated onto the printed carrier 36 if necessary.

[0073] Figure 3 shows a film 14 with two structural regions 20 that were produced by an embossing cylinder 22 according to Figure 2. It can be seen that a distance between two structural regions 20 along the length of the film 14 corresponds to the length h of the neutral region 28 of the embossing cylinder 22 as well as to the distance between two supports 36 shown in Figure 1. The length L corresponds to the length of the structural region 20 and the length h to a complete cylinder development of the embossing cylinder 22. For example, the length h, i.e. the length of the structural region 20, is a dimension that is taken into account when producing the decoration. Purely by way of example and in no way limiting, the neutral region 28 or the distance between two structural regions 20 can have a length h of, for example, 25 mm and the structure-forming region 26 or the structural region 20 can have a length h of 1300 mm.Figure 4 shows a further embodiment of a structured film 14 with a structured region 20. According to Figure 4, a lateral edge region 46 is provided, which extends along the length of the film 14. A registration mark 48, such as a registration cross, can be provided in this edge region 46, which can improve the joining of the carrier 36 and film 14. The edge region 46 can be removed after the film 14 has been applied to the carrier 36, which can be advantageous for complete coverage of the carrier 16.

[0074] List of reference symbols

[0075] 10 systems

[0076] 12 Feed unit

[0077] 14 slides

[0078] 16 rolls

[0079] 18 embossing media

[0080] 20 Structural area

[0081] 22 embossing cylinders

[0082] 24 Counter roller

[0083] 26 structurally important area

[0084] 28 Neutral zone

[0085] 30 axis

[0086] 32 Dimensioning tools

[0087] 34 Feeding device

[0088] 36 carriers

[0089] 38 decorations

[0090] 40 Data connection

[0091] 42 Merger

[0092] 44 decorative panel

[0093] 46 Marginal area

[0094] 48 registration mark

[0095] 50 arrows

Claims

Patent claims 1. A method for producing a structured decorative panel (44), comprising the following process steps: a) providing a film (14) to be structured; b) providing an embossing agent (18) for structuring the film (14); c) structuring the film (14) with the embossing agent (18) to form at least one structured area (20) on the film (14); d) determining at least one dimension of at least one structured area (20) according to process step c); e) providing a substrate (36); f) applying a decoration to the substrate (36), wherein g) when applying a decoration to the substrate (36), the at least one dimension of the structured area (20) determined in process step c) is taken into account; and h) applying the film (14) to the substrate (36) such that the at least one structured area (20) is in synchronicity with the decoration.

2. Method according to claim 1, wherein the at least one dimension comprises the length of the structural area (20).

3. Method according to claim 1 or 2, wherein the at least one dimension comprises the width of the structural area (20).

4. Method according to any of the preceding claims, wherein the film (14) comprises an acrylate-based plastic composition, in particular a polyurethane-modified acrylate plastic composition, polypropylene or polyethylene terephthalate.

5. Method according to one of the preceding claims, wherein method step f) is carried out using a digital printing process.

6. Method according to one of the preceding claims, wherein at least one of an embossing cylinder (22), an embossing band and an embossing sheet is used as the embossing means (18).

7. Method according to one of the preceding claims, wherein method step g) is carried out by using existing decor data assigned to corresponding dimensions or by performing a computational correction of decor data based on the dimension.

8. Method according to one of the preceding claims, wherein the embossing means (18) has a neutral area (28) in the longitudinal direction adjacent to at least one structure-forming area (26).

9. Method according to claim 8, wherein the neutral area (28) has at least partially a structure different from the structure-shaping area (26).

10. Method according to claim 8 or 9, wherein the neutral region (28) at least partially comprises a structure-free region.

11. Method according to any one of claims 8 to 10, wherein the film (14) is applied longitudinally to a plurality of carriers (36), wherein the carriers (36) each have a surface to be structured, wherein the surfaces to be structured of different carriers (36) are spaced apart from each other, and wherein the distance between the surfaces to be structured corresponds to the length h of a neutral region (28).

12. Method according to one of the preceding claims, wherein a registration mark (48) is applied to the decoration and to the film (14).

13. Method according to one of the preceding claims, wherein a plastic-containing carrier (36) is used as the carrier (36).

14. Method according to one of the preceding claims, wherein method parameters and dimensional change data of a film (14) are stored and compared with method parameters and dimensional change data of the film (14) or another film (14) during structuring at a later time.

15. System (10) for producing a decorative panel (44), comprising: an embossing means (18) for structuring a foil (14) to be structured, forming at least one structural area (20) on the foil (14); a dimensioning means (32) for determining at least one dimension of at least one structural area (20) after embossing the foil (14); a decorating means (38) for applying a decoration to a substrate (36), wherein, when applying the decoration to the substrate (36), the at least one dimension of the structural area (20) can be taken into account; and a joining means (42) for applying the foil (14) to the substrate (36) such that the at least one structural area (20) is in synchronicity with the decoration.

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