Method of manufacturing a panel

Patent metadata

Field	Value
Publication number	US-12290836-B2
Application number	US-202318527315-A
Country	US
Kind code	B2
Filing date	Dec 3, 2023
Priority date	Dec 22, 2021
Publication date	May 6, 2025
Grant date	May 6, 2025

Abstract

A method is provided for manufacturing a panel. The method may involve supplying a substrate having an upper side. A layer may be provided onto the upper side. The upper side may be irradiated so as to cure at least a part of the layer by irradiation, hence forming the panel. The layer may include a liquid coating on substantially the entire upper side and a substance which is digitally printed locally on the upper side. The substance and the liquid coating may cooperate such that either (1) the coating and the substance react with each other, whereas the substance is a liquid that is printed on the upper side before the coating is applied and wherein the substance and the coating have different surface tensions, or (2) the coating is non-curable or only curable to a limited extent by the irradiation, whereas the substance makes the coating curable by the irradiation at locations where they meet each other.

First claim

The invention claimed is:

1. A method for manufacturing a panel, the method comprising:
supplying a substrate having an upper side;
applying a layer onto the upper side; and
irradiating the upper side so as to cure at least a part of the layer by irradiation, hence forming the panel;
wherein the layer includes a liquid coating on the entire upper side and a substance which is digitally printed as a liquid before the coating is applied;
wherein the substance and the liquid coating react with each other; and
wherein the substance has a higher surface tension than the liquid coating; and
wherein the substance comprises a photo-initiator.

2. The method according to claim 1 , wherein the surface tension of the substance differs from the surface tension of the liquid coating in such a way that the substance and the liquid coating repel each other.

3. The method according to claim 2 , wherein a textured upper surface is created where the substance is printed.

4. The method according to claim 1 , wherein the liquid coating and the substance start to react with each other before irradiating.

5. The method according to claim 1 , wherein the substance is a varnish and/or wherein the substance comprises a photo crosslinking resin.

6. The method according to claim 1 , wherein the liquid coating is a glossy coating.

7. The method according to claim 1 , wherein the substrate is made of a wood-based material or a plastic-based material or a mineral-based material.

8. The method according to claim 1 , wherein the irradiating comprises UV irradiating.

9. The method according to claim 1 , further comprising applying a décor on the upper side before applying the layer.

10. The method according to claim 9 , wherein the décor is printed directly onto the upper side.

11. The method according to claim 9 , wherein a primer, or an alternative basecoat, is applied onto the upper side before applying the décor.

12. The method according to claim 9 , wherein the décor is applied by means of a decorative layer which is attached to the substrate.

13. The method according to claim 1 , wherein the liquid coating is transparent.

14. The method according to claim 1 , wherein the liquid coating comprises a non-photo-crosslinking material.

15. The method according to claim 1 , wherein a décor is printed directly onto the upper side; and
wherein the décor is at least partly cured before applying the layer.

16. The method according to claim 15 , wherein a primer, or any alternative basecoat, is applied onto the upper side before applying the décor.

17. The method according to claim 16 , wherein the primer is at least partly cured before applying the décor.

18. The method according to claim 1 , wherein a décor is applied by means of a decorative layer which is attached to the substrate.

Assignees

• Unilin Bv

Inventors

• Clement Benjamin
• Vermeulen Bruno

Classifications

• B44F9/00

  Designs imitating natural patterns · CPC title

• B05D2203/00

  Other substrates · CPC title

• B05D3/061

  using U.V. · CPC title

• B05D7/587

  some layers being coated "wet-on-wet", the others not · CPC title

• B05D7/577

  some layers being coated "wet-on-wet", the others not · CPC title