Method for producing a decorative laminate with a decoratively synchronously embossed surface

Abstract

A description is given of a method for producing a decorative laminate (1) with a decoratively synchronously embossed surface by means of a press using an embossing die having a three-dimensional structure, comprising the following method steps: a) retracting the embossing die in the press or another press such that the dimensions thereof substantially correspond to the operational dimensions thereof during the embossing of the surface of the decorative laminate (1), b) embossing the structure of the retracted embossing die, using pressure and temperature, into the surface of a sample laminate such that a three-dimensional surface structure is imparted to the sample laminate, c) detecting the three-dimensional surface structure of the sample laminate, preferably by scanning the three-dimensional surface structure of the sample laminate, d) developing a decoration (2) matching the detected three-dimensional surface structure, e) printing the developed decoration (2) onto a substrate (4), f) pressing the substrate (4) printed with the decoration in combination with at least one layer of material (6, 6', 10) that gives off resin under the effect of pressure and / or temperature and also in combination with a backing material (8), and optionally at least one further layer of material (12), in the press using the embossing die retracted according to method step a), while applying pressure and temperature, to form the decorative laminate (1) with the decoratively synchronously embossed surface.

Description

[0001]July 2, 2025 Method for producing decorative laminate with a decor-synchronously embossed surface The invention relates to a method for producing a decorative laminate, in particular a laminate, with a decor-synchronously embossed surface using a press and an embossing tool having a three-dimensional structure. In the context of the present invention, the term "decorative laminate" also includes coated wood-based material, for example, a sheet- or profile-shaped core material made of wood-based material, which is coated with a substrate printed with a decor. Manufacturers of laminates with decorative surfaces for various applications, for example, for floor coverings, doors, furniture, wall and ceiling coverings, regularly face the challenge ofThe decorative surface of the laminate is designed to replicate the surface of a template as realistically as possible. These templates are usually patterns of real wood or natural stone slabs, or other surfaces, such as mosaic tile coverings, grained leather, or textiles. Nowadays, it is no longer sufficient to simply imitate the template with a corresponding two-dimensional decorative image, which is achieved very well using modern printing technology. Instead, the decorative surface of the laminate is now required to have a three-dimensional structure that closely resembles the three-dimensional surface structure of the template. For decorative laminates, a surface finish where the structure and decorative image are almost identical, i.e., largely matching, is now the standard. Such a final surface finish is also known as an "embossed-in register."This surface is referred to as "synchronous pore" or a decor-synchronously embossed surface. However, achieving this surface condition is often difficult because decorative laminates are typically made using paper printed with a decor (decorative paper), which undergoes dimensional changes during the various production steps of the laminate manufacturing process. As a result, the decorative image and the embossed structure may not always align satisfactorily in the finished laminate. Decorative laminates are manufactured either discontinuously, e.g., in cycles, or continuously. In cycle-based production, for example, resin-impregnated, sheet-shaped decorative paper is combined with a sheet-shaped substrate made of paper or wood-based material and, optionally, a resin-impregnated, transparently curing overlay paper in a cycle-based press (short-cycle press) using a press plate.which has a three-dimensional embossed structure matching the decor, and is pressed into a decorative laminate using high temperatures. In contrast, in the continuous production of decorative laminate, for example, web-shaped decorative paper unwound from a roll, which is impregnated with resin after unwinding and then dried, is combined with web-shaped substrate material made of several resin-impregnated papers and optionally a web-shaped, resin-impregnated, transparently curing overlay paper in a continuous press (CPL press) using a circulating endless press belt that has a three-dimensional embossed structure matching the decor.and applied at high temperatures, continuously pressed into a decorative laminate. In the prior art, to achieve a decor-synchronized embossed surface, the printed and subsequently resin-impregnated decor paper is conventionally aligned as closely as possible with the embossing tool, e.g., press plate or press belt, which has a structure matching the decor, and is arranged in a press. A common measure for this purpose in the continuous production of decorative laminates is to align the impregnated, web-shaped decor paper (MY / dh 231164WO July 2, 2025) with the structured endless press belt during feeding into the continuous press (CPL press). However, this measure is insufficient, as it only partially counteracts the problem of the decor paper's width expansion. Positioning the impregnated, web-shaped decor paper at the press inlet does not prevent dimensional changes,These variations can occur during impregnation, drying, and pressing. However, in the continuous production of decorative laminates, achieving a decor-synchronized embossed surface presents a particular problem: when using a continuous, endless press belt with a three-dimensional embossing structure matching the decor, deviations in the length of the decor-synchronized embossing accumulate over the length of the web-shaped decor paper. The commonly used method of aligning the impregnated decor paper relative to the embossing tool using registration marks (also called registration crosses) printed on the edge of the decor paper does not achieve the desired accuracy for decor-synchronized embossing.Since this measure is typically only used to correct length variations, significant deviations in the accuracy of the match between printed decoration and embossed structure can be observed, on the order of, for example, up to approximately 10 mm. Furthermore, in continuous production, the problem also arises that errors in length accumulate. In conventional methods for producing decorative laminates, decorative paper is applied to sheet- or web-shaped substrate material using a press. The decorative paper used for this purpose is produced by applying a layer of paper to a web-shaped printing base paper that has a certain moisture content.A desired design is printed onto the paper using a printing press. The water-based printing inks used, in combination with a certain web tension of the paper in the printing press, cause the paper to expand in both length and width. After the printing process, the inks on the decorative paper are dried, for example, using infrared lamps, which sometimes leads to the printed paper drying out and thus shrinking. In the next manufacturing step, the web-shaped decorative paper is impregnated in a so-called impregnation line with a water-based, heat-curable resin, e.g., melamine resin.This causes the paper to swell. This swelling, combined with the paper's web tension, results in further expansion. The printed and impregnated paper is then dried in a drying station to a moisture content suitable for subsequent processing. This drying process partially reduces the paper's expansion. As a result, the printed, resin-impregnated, and dried paper web exhibits significant growth in both length and width. The decorative paper web is then either wound onto a reel or cut into sheets. The roll material is then processed into a decorative laminate in a continuous press (CPL press) together with a web-shaped resin-impregnated substrate, such as core paper layers, and optionally an overlay.In this process, a suitably structured press belt or a structure generator in the form of a three-dimensionally structured release film is used as a press tool to create a decor-synchronously embossed surface. The alternative sheet material, on the other hand, is processed together with sheet-shaped resin-impregnated substrate material, and optionally with an overlay, in a discontinuous press using three-dimensionally structured press plates or three-dimensionally structured release films. In each of these processing steps, the thermosetting resins crosslink under the influence of high pressure and high temperature, thus creating a material-bonded connection between the individual layers of the laminate. Due to the high temperatures, the press tools also undergo a dimensional change.which can vary considerably depending on temperature and material properties. MY / dh 231164WO July 2, 2025 Various approaches exist in the prior art for achieving the desired quality level of decorative laminate with a decor-synchronously embossed surface. EP 3495153 A describes a process for producing decorative laminate with synchronized pores, in which a paper-based substrate is printed using digital printing and the printing and position data of the printed decor are stored. The printed substrate (decor paper) is dried, then impregnated with thermosetting resin and then dried again. Subsequently, the laminate is embossed by pressing the printed,Resin-impregnated decorative paper, together with resin-impregnated core layers and optionally an overlay and / or a protective layer, is produced using a texture generator. In this known process, the dimensions of the texture generator and the dimensions of the substrate (decorative paper) are measured, and deviations of the substrate dimensions from those of the texture generator are determined. The texture generator can be, for example, a paper-based texture generator, a textured strip, or a press plate. Based on the determined deviations, at least one correction factor is calculated and transmitted to the digital printer to adjust the dimensions of the decorative element during digital printing. However, this process requires complex and sophisticated measurement, evaluation, and control technology.to reduce the dimensional changes of the decorative paper that occur during the execution of the process. Furthermore, it is unsatisfactory that this known process requires digital printing of the decorative paper and is not suitable for decorative paper produced cost-effectively by rotary printing technology. Another process for producing decorative laminate with synchronized pores is described in EP 2447064 B. This process comprises, as process steps, a continuous bonding of a carrier substrate and a film printed with a pre-defined decor, thereby obtaining a laminate, and a synchronized embossing of the laminate, wherein the embossing is synchronized with the decor of the film printed in MY / dh 231164WO 2 July 2025. The embossing is carried out by continuously passing the laminate between an engraved embossing cylinder and a counter-pressure cylinder.wherein a nominal embossing pressure exists between the embossing cylinder and the impression cylinder. Furthermore, the method comprises controls for aligning the embossing cylinder to maintain synchronization between the embossing and the decoration of the printed film, wherein a control for aligning the cylinder includes suitable alignment displacements of the embossing cylinder. The alignment displacements are carried out in combination with a temporary separation between the embossing cylinder and the impression cylinder by moving the embossing cylinder and the impression cylinder apart by a specific amount, whereby the embossing pressure is set to zero, or in conjunction with a reduction of the embossing pressure at a reduced alignment pressure that is lower than the nominal pressure. To maintain synchronization between the embossing and the decoration of the printed film, a preferred embodiment of the method provides,that the printed film does not allow for dimensional expansion. It is proposed that the printed film incorporate a rigid reinforcing fabric, preferably made of glass fibers. A disadvantage of this method is, among other things, that it requires a complex correction process, which can result in interruptions in the embossed structure or a reduction in embossing depth. Furthermore, the availability of glass fiber-based printed films as an alternative to conventional decorative paper is limited. Glass fiber-based printed films are comparatively expensive. The invention aims to provide a method for producing decorative laminates with a decor-synchronously embossed surface.with which such laminate can be produced cost-effectively at the required quality level. MY / dh 231164WO July 2, 2025 This problem is solved by a method with the features specified in claim 1. Advantageous embodiments of the method according to the invention are specified in the dependent claims referring back to claim 1. In the method according to the invention for producing decorative laminate, a decor-synchronously embossed surface is produced by means of a press using an embossing tool having a three-dimensional structure. The embossing tool can also be referred to as a structure generator. The method according to the invention comprises the following process steps: a) Inserting the embossing tool into the press or another press, so that its dimensions essentially correspond to the dimensions present during the embossing of the surface of the decorative laminate due to operational conditions,b) Embossing the structure of the inserted embossing tool into the surface of a sample laminate using pressure and temperature, so that the sample laminate acquires a three-dimensional surface structure; c) Capturing the three-dimensional surface structure of the sample laminate, preferably by scanning the three-dimensional surface structure of the sample laminate; d) Developing a decor matching the captured three-dimensional surface structure; e) Printing the developed decor onto a substrate.f) Pressing the substrate printed with the decor in combination with at least one resin-releasing material layer applied under pressure and / or temperature, a substrate, and optionally at least one further material layer in the press using the embossing tool installed according to process step a), applying pressure and temperature to produce the decorative laminate with a decor-synchronously embossed surface. MY / dh 231164WO July 2, 2025. The three-dimensional structure of the embossing tool is first applied to a base element (e.g., a base layer) of the embossing tool, matching a desired decor, before the embossing tool is installed, provided the embossing tool still needs to be manufactured. The installation of the embossing tool according to process step a) can also be referred to as calibrating the embossing tool, in particular as calibrating the embossing tool with respect to the process parameters prevailing during process step f).The embossing tool is, for example, in a state according to the invention when the dimensions of its three-dimensional structure no longer change significantly compared to the dimensions that the three-dimensional structure of the embossing tool has during the embossing of the surface of the decorative laminate. In other words, the embossing tool is in a state according to the invention, for example, when it has been exposed to the operating parameters prevailing in the press during the production of decorative laminate, including temperature, pressure, and cycle or rotation speed, as well as optionally other operating parameters such as press belt tension, for a predefinable period in the range of, for example, 1 to 8 hours, and subsequently exhibits stable dimensions. Typically, the dimensions of the embossing tool, and thus those of the structures applied to the surface of the laminate, change.when the temperature of the base element (e.g., the metal or paper) of the embossing tool changes. To achieve a precise match between surface structure and decor, it is therefore necessary to map the dimensions of the surface structure of the inserted embossing tool onto the sample laminate. MY / dh 231164WO July 2, 2025. Capturing the three-dimensional surface structure of the sample laminate according to process step c) is preferably done by scanning. Scanning produces digital image data of the three-dimensional surface structure of the sample laminate. Preferably, a color scanner is used, which captures the image data as RGB values, which are then processed with an algorithm to convert them into other colors. The method according to the invention enables the cost-effective production of decorative laminate with a decor-synchronously embossed surface at the required quality level.i.e., at a high quality level. It is characterized by the following advantages: ^Once steps a) to e) of the inventive method have been carried out, no further corrections are generally necessary during the execution of process step f). ^The pressing of the printed substrate with at least one resin-releasing material layer and a carrier material – and optionally at least one further material layer – according to step f) of the inventive method can be carried out in both a batch press (incremental press) and a continuous press (continuous press). The application of the inventive method is particularly advantageous in the continuous production of decorative laminate, preferably CPL, since the inventive method eliminates deviations in the length of the decor-synchronous embossing,which accumulate over the length of the web-shaped decorative paper in conventional methods for the continuous production of decorative laminates, can be largely eliminated. ^The pressing according to process step f) can also be carried out intermittently without an intermediate gap or, if necessary, with a small intermediate gap between successive stacks of the material layers to be bonded together to form the laminate. Such a timed pressing process, in which successive stacks of the material layers to be bonded together are pressed without an intermediate gap or with a small intermediate gap according to process step f),can also be considered or evaluated as a quasi-continuous pressing process.^ The application of the inventive method with regard to printing the developed decor according to process step e) is neither limited to digital printing technology nor to rotary printing technology; rather, process step e) can be carried out using both digital printing technology and rotary printing technology.^ In the inventive method, by embossing a surface structure into a sample laminate using an embossing tool inserted according to process step a) and by developing (generating) the decor of the decorative laminate to be produced based on the captured surface structure of the sample laminate, real dimensional changes of the embossing tool at operating temperature compared to the dimensions of the embossing tool at room temperature are taken into account.without the need to use calculated values ​​to determine these dimensional changes of the embossing tool.^ The method according to the invention is considerably simpler and more cost-effective compared to prior art methods of the same type, which use calculated correction factors to achieve a decor-synchronously embossed laminate surface at the desired quality level. Calculating suitable correction factors to achieve a decor-synchronously embossed laminate surface at a high quality level is complex and time-consuming.^ While prior art methods of the same type, which use calculated correction factors to achieve a decor-synchronously embossed laminate surface at the desired quality level,While conventional methods sometimes only allow limited corrections to reduce dimensional changes (e.g., increasing the web tension to lengthen impregnated decorative paper and thus reduce the width growth of the decorative paper simultaneously causes an undesirable increase in the length growth of the decorative paper), the inventive method can largely minimize the misalignment between the decor and the embossed structure of the laminate, both in length and width, of the decorative, three-dimensionally embossed laminate. An advantageous embodiment of the inventive method is characterized in that the substrate printed with the decor is fed to the press without a subsequent resin impregnation step and is pressed there with the at least one resin-releasing material layer and the substrate, and optionally with the at least one further material layer.Using the embossing tool inserted according to step a), and applying pressure and temperature, the decorative laminate with a decor-synchronously embossed surface is pressed. In other words, the substrate printed with the decor is not impregnated with resin before pressing. The substrate printed with the decor is thus fed to the press as a printed, dry substrate and processed (pressed) there with the other material layers mentioned above, and optionally with at least one further material layer, to form a laminate. With regard to the printed substrate, this embodiment of the invention thus provides for a dry pressing process. During the pressing process, resin from the at least one resin-releasing material layer is at least partially transferred to the printed, dry substrate. This embodiment of the invention prevents dimensional changes in the printed substrate caused by swelling.which can be, in particular, decorative paper, largely or even essentially completely prevented. Accordingly, this embodiment allows for a particularly high quality level of the laminate with regard to the decor-synchronous conformity of its embossed three-dimensional surface structure with the printed decor. MY / dh 231164WO July 2, 2025. Another advantageous embodiment of the method according to the invention provides that the sample laminate has a material structure that corresponds to that of the decorative laminate. Internal tests by the applicant have shown that this embodiment also allows for a particularly high quality level of the laminate with regard to the decor-synchronous conformity of its embossed three-dimensional surface with the printed decor. Another advantageous embodiment of the method according to the invention essentially consists inthat a laminate is used as the sample laminate whose material structure includes an unprinted substrate. This facilitates optical detection, in particular scanning, of the three-dimensional surface structure of the sample laminate and thus improves the quality of the optical detection or scanning result. The result is crucial for the subsequent decor development. If, on the other hand, a sample laminate is used whose material structure includes a printed substrate, the printed decor image can impair scanning of the three-dimensional surface structure, which can then negatively affect the image quality of the decor developed based on the scan result. The embossing tool used to carry out the method according to the invention can be, for example, a press belt, a structuring paper, or a structuring film.an embossing roller or a press plate. If a structuring paper or a structuring film is used as an embossing tool in the inventive method, such an embossing tool can be used, in particular, in the form of roll stock. The embossing tool, designed in the form of roll stock, is first unwound from a roll and inserted as a web-shaped embossing tool into a press according to process step a), wherein the press is designed as a continuous press. Viewed in the direction of travel through the press, the web-shaped embossing tool is wound up into a roll (roll stock) behind the press. Process step a) is repeated several times if necessary.until the embossing tool essentially reaches its final dimensions. The inventive method is not limited to the use of a specific type of press. Process step a) and / or process step f) of the inventive method can be carried out in a continuous press (e.g., a double-belt press) or alternatively in a discontinuous press, in particular in a pulsed press, e.g., a short-cycle press or a multi-deck press. Continuous production of laminate (composite material), also called CPL (Continuous Pressed Laminate), has the advantage that laminates can be produced independently of length cutting. In addition, the production of laminate in a continuous press, for example, a continuously operating double-belt press, enables online post-processing of the produced laminate (CPL). CPL can be cut to width online, immediately after pressing,The back side can be sanded and / or cut to length. Custom lengths can be produced flexibly and economically. Furthermore, it is possible to manufacture thin laminates with thicknesses ranging from, for example, 0.15 to 0.5 mm and to supply relatively thin laminates as roll stock. In addition, roll stock can be advantageously processed further using continuous methods, such as applying it to substrate boards. A discontinuous press, such as a short-cycle or multi-stage press, allows for a relatively high pressing pressure in the range of, for example, 50 to 80 bar, and especially 70 to 80 bar. This makes it possible to produce so-called high-pressure laminates (HPL), particularly thicker laminates.such as producing compact panels with thicknesses in the range of, for example, 2 to 40 mm. MY / dh 231164WO July 2, 2025. In process step a), the embossing tool is preferably inserted multiple times or until it essentially reaches its final dimensions, which it possesses during the embossing of the surface of the decorative laminate. For this purpose, an advantageous embodiment of the method according to the invention provides that the insertion of the embossing tool is carried out by multiple, for example, at least three, applications of the embossing tool in successive pressing operations. The implementation of the method according to the invention is not limited to the application of a specific printing technique for printing the decor developed on the basis of the three-dimensional surface structure of the sample laminate. Rather, the method according to the invention allows the developed decor to be printed by means of digital printing, preferably inkjet printing,or can be printed onto the substrate using rotary printing (e.g., rotogravure or offset printing). Printing the decor developed according to the invention using digital printing is particularly advantageous when relatively small batch sizes of decorative laminate are frequently produced or when the three-dimensional surface structure and a matching printed decor are frequently changed. Digital printing allows for quick access to the print data with short production times. In contrast, printing the decor developed according to the invention using rotary printing with a printing cylinder or ink roller is particularly advantageous when large batch sizes of the decor are to be produced for large batch sizes of decorative laminate. Furthermore, rotary printing enables particularly high print quality.In particular, a sharp-edged print without jagged edges of printed decorative elements. Various materials, especially composite materials, can be used as the substrate in the inventive process. For example, the substrate in the inventive process can be paper, pre-impregnated material, cardboard, paper- or cellulose-based material, film, nonwoven fabric, and / or textile material. In the case of paper, this can correspond to the initially unprinted and unresin-free paper of a decorative paper or the unprinted and unresin-free paper of an overlay paper, wherein this paper, as the substrate, is then preferably fed to the press after the developed decoration has been printed, without a subsequent resin impregnation step. The substrate is preferably relatively thin, for example, as thin paper with a thickness in the range of approximately 0.03 to 0.1 mm. In other words,The substrate used according to the invention, for example a paper-based or paper / cellulose-based substrate onto which the decoration is printed, has a basis weight in the range of approximately 1 to 120 g / m², in particular approximately 1 to 100 g / m², preferably in the range of approximately 10 to 70 g / m², and particularly preferably in the range of 20 to 50 g / m². According to an advantageous embodiment of the invention, a so-called pre-impregnated substrate is used as the substrate in the inventive process. The pre-impregnated substrate is a paper-based substrate (decoration base paper). A resin is added during the paper production process. The pre-impregnated substrate contains, for example, acrylic resin. A pre-impregnated substrate suitable for use in the inventive process is described, for example, in EP 2537682 B1.whose disclosure content is fully incorporated into the present description of the invention by reference. Such pre-impregnated materials are characterized by high splitting resistance and universal adhesion in various laminating processes. Furthermore, such pre-impregnated materials are easily printable and do not undergo any further dimensional changes in subsequent process steps that would be detrimental to the production of a decor-synchronously embossed laminate. Such pre-impregnated materials have, for example, a basis weight in the range of 40 to 120 g / m². Where an overlay is mentioned below, this refers to an overlay paper impregnated with resin (synthetic resin). This overlay (overlay impregnated material) serves as protection for the printed decorative image of the laminate and as a resin-releasing material layer (through the action of pressure and / or temperature). MY / dh 231164WO July 2, 2025. If an unreinforced overlay paper is used as the substrate,This paper is preferably not used as the top layer of the decorative laminate. A further advantageous embodiment of the method according to the invention is characterized in that an underlay impregnated with thermosetting resin is introduced between the substrate and the substrate printed with the decoration. Such an underlay enables a permanent, material-bonded connection between the substrate and the substrate if the underlay is designed as a resin-releasing material layer that releases resin under the influence of pressure and / or temperature. The substrate itself does not need to have any adhesive properties, in particular no adhesive properties that can be activated by pressure and / or temperature. Thus, this embodiment increases the number of suitable substrate materials for the production of decorative laminates with a surface embossed in sync with the decoration. However, the invention particularly includes embodiments thatin which a resin-impregnated substrate or a substrate with adhesive properties that can be activated by pressure and / or temperature is used as the carrier material. In this embodiment of the inventive method, the printed substrate can be a substrate not impregnated with resin or a pre-impregnated substrate of the type described above. In this context, a further advantageous embodiment of the inventive method provides that the underlay is a solid-color paper impregnated with thermosetting resin. By selecting a specific color of the solid-color paper in combination with the decoration printed on the substrate, a two- or multi-layered overall decoration can be achieved.which gives the laminate the optical effect of a certain decorative depth. The solid-colored paper (underlay) impregnated with thermosetting resin can also be referred to as the base layer. Furthermore, or alternatively, the underlay can serve as a barrier to prevent chemical interaction between different resins of the decorative laminate. Another advantageous embodiment of the method according to the invention provides that an overlay made of a transparently curing material layer impregnated with thermosetting resin, preferably a paper layer, is applied as the top layer of the decorative laminate. Preferably, this overlay is applied directly to the substrate printed with the decor without an intermediate layer. The transparently curing overlay protects the decor from mechanical and chemical influences.in particular against abrasion. In addition, the decor is protected from excessive mechanical stress or damage by the overlay during the pressing of the superimposed laminate layers according to step f) of the inventive method. The substrate material used in the inventive method is or is formed, for example, from paper, kraft papers, cardboard, parchment and / or nonwovens, in particular glass fiber nonwovens, and / or a wood-based substrate. Preferably, the substrate material used in the inventive method is such a substrate material that is or is impregnated with thermosetting resin, wherein the thermosetting resin is a phenol-formaldehyde resin, a melamine-formaldehyde resin, a urea-formaldehyde resin, or a mixture of at least two such formaldehyde resins. A further advantageous embodiment of the inventive method provides that the substrate material is a wood-based panel, a fiberboard,Preferably an MDF or HDF board, a particleboard and / or an OSB board or a composite board made of at least two such wood-based panels is used. The laminate produced according to the invention acquires high mechanical strength properties through such a substrate material and is therefore particularly suitable for the production of floor panels and furniture panels. MY / dh 231164WO July 2, 2025. In the process according to the invention, the pressing of the substrate printed with the decor to form the decorative laminate takes place at a pressing temperature, for example in the range of 160 to 210°C.preferably in the range of 180 to 200°C. According to a further advantageous embodiment of the invention, the substrate printed with the decoration is or is provided with at least one or more registration marks. In order to achieve three-dimensional surface structure elements of the laminate corresponding to the decoration, the embossing tool is aligned with respect to the at least one registration mark. This alignment may only need to be carried out once, since – after carrying out process steps a) to e) of the inventive method – no further corrections are generally necessary during the execution of process step f). The invention is explained in more detail below with reference to a drawing illustrating several exemplary embodiments. Figure 1 shows a section of a decorative laminate with a surface embossed synchronously with the decoration.in a cross-sectional view; Fig. 2 shows a section of a decorative laminate with a decor-synchronously embossed surface according to one variant, in a cross-sectional view; and Fig. 3 shows a section of a decorative laminate with a decor-synchronously embossed surface according to another variant, in a cross-sectional view. The drawing shows exemplary embodiments (variants) of a decorative laminate 1 produced according to the invention. The laminate 1 consists of a substrate 4 printed with a decor 2, at least one resin-releasing material layer 6, and a carrier material 8. Optionally, the laminate structure can comprise at least one further material layer.For example, a paper-based overlay 10 impregnated with thermosetting resin serves as the top layer, and / or a paper-based or paper-based backing layer 12 serves as the backing. Depending on the properties of the substrate material 8, the optional backing layer 12 can be made of, for example, non-impregnated paper, particularly parchment paper, or resin-impregnated paper. The substrate material 8 consists, for example, of several layers 8.1, 8.2, 8.3, 8.4, 8.5 of paper impregnated with thermosetting resin, preferably resin-impregnated kraft paper (see Figures 1 and 2). These thermosetting resin-impregnated layers 8.1, 8.2, 8.3, 8.4, 8.5 can also be referred to as core layers. Alternatively, a wood-based panel, for example an MDF or HDF panel or a particleboard, can be used as the carrier material 8 or core layer in the laminate structure (see Fig. 3). With the thermosetting resin,The resin with which the substrate 8 is impregnated or which the substrate 8 contains is, for example, phenol-formaldehyde resin, melamine-formaldehyde resin, urea-formaldehyde resin, or a mixture of at least two such formaldehyde resins. The substrate 4 is preferably a sheet material that can be printed with a decor 2, in particular wood decor, stone decor, tile decor, or fantasy decor, using at least one printing process. Examples of the substrate 4 used in the laminate structure according to the invention are substrates made of paper, pre-impregnated material, cardboard, paper- or cellulose-based material, film, nonwoven fabric, and / or textile material. The decor 2 is or was applied to the substrate 4 using digital printing technology, for example, inkjet printing technology, or using rotary printing technology, for example, rotogravure printing technology.Printed. MY / dh 231164WO July 2, 2025. A three-dimensional structure 14, matching the decor 2, is embossed into the top surface of the laminate 1. The decorative laminate thus has a decor-synchronized embossed surface. The embossing of the three-dimensional structure 14 into the top surface of the laminate structure is carried out in a press using an embossing tool having a three-dimensional structure. The embossing tool can be, for example, in the form of a press belt, a structuring foil, a structuring paper, an embossing roller, or a press plate. The pressing of the substrate 4, printed with the decor 2, with the carrier material 8 to form the decorative laminate 1 takes place at a pressing temperature that is, for example, in the range of 160 to 210°C, preferably in the range of 180 to 200°C. The pressing of the aforementioned material layers to form the decorative laminate 1 takes place in a continuous press or in a batch press.for example, a press operating in a clocked fashion. In the inventive method for producing a decorative laminate 1 with a decor-synchronously embossed surface, the decor 2 to be printed onto the substrate 4 is developed in a special way to match the three-dimensional structure of the embossing tool. For this purpose, for example, the embossing tool is first provided with a three-dimensional structure matching a desired decor by applying the structure to a base element or base layer of the embossing tool. For example, the three-dimensional structure can be engraved into a surface of the embossing tool or created on a surface of the embossing tool by an etching process. Alternatively, in the inventive method for producing a decorative laminate 1 with a decor-synchronously embossed surface, an already existing,The starting point is an embossing tool with a three-dimensional structure. This embossing tool is then calibrated in the press intended for the production of the decorative laminate 1, for example, a continuous press (MY / dh 231164WO July 2, 2025), or in another press, so that the dimensions of the embossing tool, at least the dimensions of its three-dimensional structure, essentially correspond to the dimensions present during the embossing of the surface of the decorative laminate 1. The embossing tool is calibrated, for example, by multiple applications of the embossing tool in successive pressing operations. If the embossing tool is, for example, a texturizing paper, three to four or even more successive pressing operations with the texturizing paper may be necessary.until it reaches sufficiently stabilized dimensions. New texturizing paper shrinks during the first pressing operations until its dimensions stabilize. If texturizing paper or film is used as an embossing tool in the inventive method, it is preferably used in roll form. A new texturizing paper or film is first unwound from a roll and fed into a continuous press as a web-shaped embossing tool under the influence of pressure and temperature. Viewed in the direction of travel of the press, the web-shaped embossing tool is wound up into a roll (roll material) behind the press. This feeding of the embossing tool is repeated as often as necessary.until it reaches sufficiently stable dimensions for its subsequent intended use. Then, the three-dimensional structure of the calibrated embossing tool is embossed into the surface of a sample laminate using pressure and temperature, so that the sample laminate acquires a three-dimensional surface structure. The material composition of the sample laminate preferably corresponds substantially to that of the decorative laminate 1 to be produced subsequently. The three-dimensional surface structure of the sample laminate serves as a template for the decor 2 to be developed for the decorative laminate 1 to be produced. The sample laminate itself does not need to have a printed decor. An advantageous embodiment of the method according to the invention provides thatThe sample laminate, containing an unprinted substrate, is produced using the embossing tool. The sample laminate produced with the embossing tool therefore preferably contains no printed decoration. Subsequently, the three-dimensional surface structure of the sample laminate is captured. This capture is preferably performed by scanning. Scanning provides digital image data of the three-dimensional surface structure of the sample laminate. For example, a color scanner is used, which captures the image data as RGB values, which are then processed by an algorithm to convert them into other colors. Based on the captured three-dimensional surface structure of the sample laminate, a decoration 2 matching the surface structure is developed. The developed decoration 2 is then printed onto a substrate 4.the component of the material structure of the decorative laminate 1 to be produced. The decoration 2 is printed onto the substrate 4 by rotogravure or digital printing, in particular inkjet printing. For rotogravure printing, a required number of ink rollers are produced, with which various partial images or base colors of the decoration 2, developed based on image data of the surface structure of the sample laminate, are printed. Subsequently, the substrate 4 printed with the decoration 2 is combined with at least one resin-releasing material layer 6, which releases resin under the influence of pressure and / or temperature, and a substrate 8 of the type mentioned above, and optionally at least one further material layer (10,12) in the press, using the inserted embossing tool and applying pressure and temperature, to form the decorative laminate 1 with a decor-synchronously embossed surface. The resin-releasing material layer 6 can also be referred to as the adhesive layer. MY / dh 231164WO July 2, 2025. The substrate 4 printed with the decor 2 is fed into the press without subsequent resin impregnation and pressed into the decorative laminate 1 together with the other material layers 6, 8 and, if applicable, 10, 12, using the inserted embossing tool and applying pressure and temperature. The printed substrate 4 fed into the press thus contains no resin that could cause the substrate 4 to swell or the printed decor 2 to change dimensions. The printed substrate 4 is therefore dry, i.e., considered on its own without aqueous,thermosetting resin is pressed. Optionally, the printed substrate 4 fed to the press can be based on a pre-impregnated material. The pre-impregnated material is, for example, a paper substrate (decorative base paper). A resin is added during the paper production process. After at least partial curing or drying of the resin, the decoration developed according to the invention is printed onto the pre-impregnated material. The decorative laminate 1 produced according to the invention has a surface embossed in sync with the decoration, since no critical dimensional changes of the printed substrate 4 occur in the manufacturing process according to the invention, and the three-dimensional structure of the embossing tool was reproduced under process conditions, in particular at a temperature ofwhich essentially corresponds to the process temperature during hot pressing. Fig. 1 shows an embodiment of a decorative laminate 1 produced according to the invention. The laminate 1 is, for example, a CPL produced in a continuously operating double-belt press. The laminate 1 has the following material structure (layer structure): A resin-impregnated base layer is applied as a resin-releasing material layer 6 to the top side of a substrate material (core) 8. The substrate material 8 is formed from a plurality of resin-impregnated paper layers 8.1, 8.2, 8.3, 8.4, 8.5, for example, kraft papers, which are also called core layers. The resins with which the core layers are impregnated can be relatively elastic thermosetting resins, for example, phenol-formaldehyde resins. The base layer 6 is preferably made with melamine-formaldehyde resin (MF resin),The base layer 6 is impregnated with urea-formaldehyde resin (UF resin) or a mixture thereof (MUF resin). The base layer 6 is preferably a solid color, for example, beige, brown, or reddish-brown. A substrate 4 printed with a decor 2 is applied to the base layer 6. The decor 2 imitates, for example, a wood grain or natural stone grain. The decor 2 was developed according to the inventive method to match the three-dimensional surface structure of a sample laminate, which was embossed into the surface of the sample laminate by means of the embossing tool according to the invention. The substrate 4 is a non-impregnated, preferably transparent substrate, for example, a non-impregnated, transparent paper. The printing material 4, for example, has a basis weight in the range of 1 to 120 g / m², in particular from 1 to 100 g / m², preferably in the range of 10 to 70 g / m²,Particularly preferred in the range of 20 to 50 g / m². The printed decor 2 is located on the top surface of the substrate 4. The decor 2 is not applied to the entire surface of the transparent substrate 4, but leaves areas of the substrate 4 uncovered, through which the solid-color base layer 6 remains visible. The base layer 6 can also be referred to as an underlay or resin-impregnated solid-color decor layer; its primary function is as a resin-releasing material layer 6, triggered by pressure and / or temperature. The resin-releasing material layer 6 acts as a double-sided adhesive layer. A resin-impregnated overlay 10 is arranged on the substrate 4 printed with the decor 2 as the top layer of the decorative laminate 1. The overlay 10 consists of a transparently curing material layer impregnated with a thermosetting resin (e.g., melamine resin).preferably a paper layer is formed. The base material (paper layer) of the overlay 10 has a high resin absorption capacity. The overlay 10 is applied directly to the substrate 4 printed with the decor 2 MY / dh 231164WO July 2, 2025, without an intermediate layer. A three-dimensional surface structure 14 is embossed into the overlay 10 using the embossing tool inserted according to the invention. On an underside (back side) of the laminate 1, which faces away from the decor 2, the substrate 8 is optionally provided with a material layer 12 acting as a counter-tension. The material layer 12 serving as a counter-tension is preferably formed from non-impregnated paper, for example, parchment paper. The thickness of the material layer 12 can correspond approximately to the total thickness of the layers 6, 4, 10 arranged on the top side of the substrate 8. The counter-tension created by the material layer 12 prevents, if necessary,that the laminate 1, produced at a high pressing temperature, warps upon cooling due to differing stresses in the substrate material 8 and in the layers 6, 4, 10. Figure 2 shows a further embodiment of a decorative laminate 1 produced according to the invention with a decor-synchronously embossed surface. This laminate 1 can also be a CPL produced in a continuously operating double-belt press. The material structure (layer structure) of the laminate 1 shown in Figure 2 differs from the material structure of the laminate 1 shown in Figure 1 with regard to the layers 4, 5, 6, 7, 8, 9, 10 arranged between the substrate material (core) 8 and the overlay 10.6. In the variant according to Fig. 2, a resin-impregnated underlay 6' is first applied to one upper side of the carrier material 8. In this variant, the underlay 6' essentially functions as a resin-releasing material layer 6 under the influence of pressure and / or temperature. The underlay 6' acts like a double-sided adhesive layer. It is based on a paper layer, preferably coated with a relatively elastic thermosetting resin, for example, a melamine-formaldehyde resin.is impregnated with urea-formaldehyde resin or a mixture thereof. MY / dh 231164WO July 2, 2025 A substrate 4 printed with a decor 2 is applied to the resin-releasing underlay 6'. The substrate 4 is preferably paper. The substrate 4 printed with a decor 2 can therefore optionally also be referred to as decor paper. The decor 2 imitates, for example, a wood or stone surface. The decor 2 was in turn developed according to the inventive method to match the three-dimensional surface structure of a pattern laminate, wherein this surface structure was previously embossed into the surface of the pattern laminate by means of the inserted embossing tool. The substrate 4 printed with the decor 2 is not resin-impregnated; it is therefore preferably non-impregnated, dry decor paper. The printing material (decorative paper) 4, for example, has a basis weight in the range of 30 to 120 g / m²,preferably in the range of 40 to 80 g / m². The printed decoration 2 is located on the top side of the substrate (paper) 4. A resin-impregnated overlay 10 is arranged on the printed substrate 4 as the top layer (cover layer) of the laminate 1. The overlay 10 of the laminate structure shown in Fig. 2 corresponds to the overlay 10 of the laminate structure shown in Fig. 1. The three-dimensional surface structure 14, which was embossed into the overlay 10 by means of the embossing tool inserted according to the invention, is designated by 14. In the variant of the decorative laminate 1 shown in Fig. 2, a material layer 12 acting as a counter-tension, as in the embodiment shown in Fig. 1, can also optionally be placed on the underside of the substrate (core) 8.be applied in a material-bonded manner. Another embodiment of a decorative laminate 1 produced according to the invention with a decor-synchronously embossed surface is shown in Fig. 3. The material structure (layer structure) of the laminate 1 shown in Fig. 3 differs from the material structure of the laminate 1 shown in Fig. 1 with regard to the substrate material 8. In the variant of the laminate 1 produced according to the invention shown in Fig. 3, the substrate material 8 is made of wood-based material, for example, particleboard or an MDF or HDF board. MY / dh 231164WO July 2, 2025. On the back side of the laminate 1, the substrate material 8 is provided with a material layer 12 acting as a counter-layer. In this case, the material layer 12 consists of a resin-impregnated material layer.preferably made of resin-impregnated paper. The thickness of the material layer 12 corresponds approximately to the total thickness of the layers 6, 4, 10 arranged on the top side of the substrate material 8. The embodiment of the invention is not limited to the exemplary embodiments shown in the drawing. Rather, numerous other variants of the method according to the invention are conceivable, which also make use of the subject matter of the invention disclosed in the claims in a configuration that differs from the examples shown. For example, it is also within the scope of the invention that the substrate 4 printed with the decoration 2 is or is provided with one or more registration marks, wherein, in order to achieve three-dimensional surface structure elements of the laminate 1 corresponding to the decoration 2, the embossing tool is aligned with respect to the at least one registration mark. MY / dh 231164WO July 2, 2025

Claims

July 2, 2025 Patent Claim 1. Method for producing a decorative laminate (1) with a decor-synchronously embossed surface using a press and an embossing tool having a three-dimensional structure, comprising the process steps of: a) inserting the embossing tool into the press or another press so that its dimensions substantially correspond to the dimensions present during the embossing of the surface of the decorative laminate (1), b) embossing the structure of the inserted embossing tool into the surface of a sample laminate by applying pressure and temperature, so that the sample laminate acquires a three-dimensional surface structure, c) capturing the three-dimensional surface structure of the sample laminate, preferably by scanning the three-dimensional surface structure of the sample laminate, d) developing a decor (2) matching the captured three-dimensional surface structure,e) Printing the developed decor (2) onto a substrate (4), f) Pressing the substrate (4) printed with the decor (2) in combination with at least one resin-releasing material layer (6, 6', 10) and a carrier material (8), and optionally at least one further material layer (12), in the press using the embossing tool inserted according to process step a) and applying pressure and temperature to produce the decorative laminate (1) with a decor-synchronously embossed surface. - 2 - 2. Method according to claim 1, wherein the substrate (4) printed with the decoration (2) is fed to the press without a subsequent resin impregnation step and is pressed in the press with the at least one resin-releasing material layer (6, 6', 10) and the carrier material (8), and optionally the at least one further material layer (12), using the embossing tool inserted according to step a) and applying pressure and temperature to form the decorative laminate (1) with a surface embossed in sync with the decoration.

3. Method according to claim 1 or 2, wherein the sample laminate has a material structure corresponding to that of the decorative laminate (1).

4. Method according to any one of claims 1 to 3, wherein the sample laminate is a laminate whose material structure comprises an unprinted substrate (4). 5.A method according to any one of claims 1 to 4, wherein a press belt, a structuring paper, a structuring foil, an embossing roller, or a press plate is used as the embossing tool.

6. A method according to any one of claims 1 to 5, wherein process step a) and / or process step f) are carried out in a continuous press.

7. A method according to any one of claims 1 to 5, wherein process step a) and / or process step f) are carried out in a discontinuous press, preferably a pulsed press.

8. A method according to any one of claims 1 to 7, wherein the insertion of the embossing tool is carried out by multiple, preferably at least three, MY / dh 231164WO July 2, 2025. - 3 - The embossing tool is used in successive pressing operations.

9. A method according to any one of claims 1 to 8, wherein the developed decoration (2) is printed onto the substrate (4) by means of digital printing or rotary printing.

10. A method according to any one of claims 1 to 9, wherein the substrate (4) is a substrate made of paper, pre-impregnated material, cardboard, paper- or cellulose-based material, film, nonwoven fabric and / or textile material.

11. A method according to any one of claims 1 to 10, wherein the substrate (4) onto which the decoration (2) is printed or has been printed has a basis weight in the range of 1 to 120 g / m², preferably in the range of 10 to 70 g / m², particularly preferably in the range of 20 to 50 g / m². 12.A method according to any one of claims 1 to 11, wherein an underlay (6, 6') impregnated with thermosetting resin is inserted between the substrate (8) and the substrate (4) printed with the decoration (2), wherein the underlay (6, 6') is preferably inserted directly under the side of the substrate (4) facing the substrate (8) without an intermediate layer. A method according to claim 12, wherein the underlay (6) is a single-color paper impregnated with thermosetting resin.

14. A method according to any one of claims 1 to 13, wherein an overlay (10) made of a transparently curing material layer, preferably a paper layer, impregnated with thermosetting resin, is applied as the top layer of the decorative laminate (1), wherein the overlay (10) is preferably applied directly to the substrate (4) printed with the decoration (2) without an intermediate layer. MY / dh 231164WO July 2, 2025.

15. A method according to any one of claims 1 to 14, wherein the substrate material (8) is or is formed from paper, kraft paper, cardboard, parchment and / or nonwoven fabric, in particular glass fiber nonwoven fabric, and / or a wood-based substrate.

16. A method according to any one of claims 1 to 15, wherein the substrate material (8) is such a substrate material that is or is impregnated with thermosetting resin, wherein the thermosetting resin is a phenol-formaldehyde resin, a melamine-formaldehyde resin, a urea-formaldehyde resin, or a mixture of at least two such formaldehyde resins.

17. A method according to any one of claims 1 to 16, wherein the substrate material (8) is a wood-based panel, in particular a fiberboard, preferably an MDF or HDF panel, a particleboard and / or an OSB panel, or a composite panel made of at least two such wood-based panels. 18.A method according to any one of claims 1 to 17, wherein the pressing of the substrate (4) printed with the decoration (2) with the carrier material (8) to form the decorative laminate (1) takes place at a pressing temperature in the range of 160 to 210°C, preferably in the range of 180 to 200°C. A method according to any one of claims 1 to 18, wherein the substrate (4) printed with the decoration is or is provided with one or more registration marks, and wherein, in order to achieve three-dimensional surface structure elements of the laminate (1) corresponding to the decoration (2), the embossing tool is aligned with respect to the at least one registration mark. MY / dh 231164WO July 2, 2025.

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