Process and device for the production of layered materials with synchronous-pore effect

Patent metadata

Field	Value
Publication number	US-10899167-B2
Application number	US-201816210251-A
Country	US
Kind code	B2
Filing date	Dec 5, 2018
Priority date	Dec 11, 2017
Publication date	Jan 26, 2021
Grant date	Jan 26, 2021

Abstract

Disclosed is a process for the production of synchronous-pore layered materials. Also disclosed is a device for the conduct of the process. In further aspects, the invention relates to layered materials which can be produced by the process, and also to wood-composite boards equipped with the layered materials produced by the process of the invention.

First claim

The invention claimed is:

1. A process for the continuous production of synchronous-pore layered materials, comprising the steps of:
a) producing a layered material, comprising the steps of
i. printing a carrier material by means of digital printing and storing print data and/or positional data of a printed decorative effect;
ii. drying the printed carrier material;
iii. applying and drying an impregnation material onto the printed carrier material; and
iv. producing a layered material, comprising pressing the printed and impregnated carrier material together with impregnated core plies and optionally an overlay and optionally a protective layer, with the use of a structure-former;

b) measuring the dimensions of the structure-former;
c) measuring the dimensions of the carrier material;
d) determining deviations of the dimensions of the carrier material from the dimensions of the structure-former;
e) calculating at least one correction factor K, wherein
measurements are made of deviations in the length and/or the width of the carrier material from the length and/or the width of the structure-former after application of the printed decorative effect to the carrier material, and a partial correction factor k a is determined with reference to these dimensional changes;
and
measurements are made of deviations in the length and/or the width of the carrier material from the length and/or the width of the structure-former after drying of the printed carrier material, and a partial correction factor k b is determined;
and
measurements are made of deviations in the length and/or the width of the carrier material from the length and/or the width of the structure-former after the application and drying of the impregnation material onto the printed carrier material, and a partial correction factor k c is determined,
and
the correction factor K is calculated from formula (I):
K=k a +k b +k c +k d   (I),

where
k d can be present or absent, and if present is the partial correction factor resulting from one or more further process steps; and
k a , k b , k c , and k d respectively mutually independently can be 0 or a positive or negative number in percent;

f) communicating the at least one correction factor K to a digital printer; and
g) using the at least one correction factor K for appropriate adjustment of the dimensions of the decorative effect during the digital printing step.

2. The process as claimed in claim 1 , where the layered material is a high-pressure laminate.

3. The process as claimed in claim 1 , where the structure-former is a structure-former based on paper or a structuring belt or a press platen.

4. The process as claimed in claim 1 , wherein the dimensions of the structure-former and of the carrier material are measured with reference to a longitudinal repeat distance and/or a transverse repeat distance and/or with the aid of positional marks.

5. The process as claimed in claim 1 , wherein in all of the manufacturing stages a) i. to a) iv., deviations of the length and/or the width of the carrier material from the length and/or the width of the structure-former are determined according to step d).

6. The process as claimed in claim 1 , wherein the partial correction factors are calculated mutually independently from formula (II):

k
x

⁡

(

D
⁢

⁢
2

D
⁢

⁢
1

⋆

100
⁢
%

)

-

100
⁢
%

(
II
)

where
k x is a partial correction factor selected from k a , k b , k c , and k d ;
D2 is the length or width of the carrier material after implementation of the respective process step a) i. to a) iv; and
D1 is the length or width of the structure-former,
and D1 and D2 are the length of carrier material and of structure-former, or are the width of the carrier material and structure-former.

7. The process as claimed in claim 1 , wherein measurements are made of deviations in the length and/or width of the carrier material from the length and/or the width of the structure-former after the press procedure, and a resultant partial correction factor k d is determined.

8. The process as claimed in claim 6 , wherein a correction factor K L for the length change and, separately, a correction factor K W for the width change of the carrier material are calculated with reference to the formulae (I) and (II).

9. The process as claimed in claim 1 , wherein deviations in the dimensions of the carrier material are compensated via control of the process parameters.

10. The process as claimed in claim 1 , wherein the layered material is produced continuously in a continuous press (CPL press).

11. The process as claimed in claim 1 , wherein the printed carrier material, to which an overlay has optionally been provided, is converted to smaller formats by means of cutting-to-size equipment, and wherein positioning of the carrier material for the production of smaller formats in the cutting-to-size equipment is undertaken with reference to a positional mark.

12. The process as claimed in claim 2 , where the structure-former is a structure-former based on paper or a structuring belt or a press platen.

13. The process as claimed in claim 6 , wherein measurements are made of deviations in the length and/or width of the carrier material from the length and/or the width of the structure-former after the press procedure, and a resultant partial correction factor k d is determined.

14. The process as claimed in claim 1 , wherein the carrier material comprises a decorative paper.

15. The process as claimed in claim 8 , wherein the dimensions of the printed decorative effect in the digital print are compressed or expanded by means of using the correction factor K L in respect of the length and/or of the correction factor K W in respect of the width.

16. The process as claimed in claim 9 , wherein the process parameters comprise at least one of: drying, web tension, production rate, press pressure, and/or press temperature.

Assignees

• Flooring Technologies Ltd

Inventors

• Kalwa Norbert
• Hasch Joachim
• Stiewe Bernd

Classifications

• B41M5/0005 Primary

  Enlarging or reduction of graphic information on a support by stretching or contracting the support, optionally in combination with the recording · CPC title

• B44C5/0492 Primary

  containing wooden elements · CPC title

• B32B41/00 Primary

  Arrangements for controlling or monitoring lamination processes; Safety arrangements · CPC title

• B44C5/0469

  comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper · CPC title

• B44C1/24

  Pressing or stamping ornamental designs on surfaces · CPC title