Process for the manufacturing of surface elements

Abstract

A process for the manufacturing of surface elements ( 1 ) which comprises a decorative upper layer ( 2 ) and a supporting core ( 5 ). A supporting core ( 5 ) with a desired format is manufactured and provided with an upper side ( 1 ′) and a lower side ( 4 ). The upper side ( 1 ′) of the supporting core ( 5 ) is provided with a décor, by for example printing, which décor ( 2 ′) is positioned after a predetermined fixed point on the supporting core ( 5 ). The upper side ( 1 ′) of the supporting core ( 5 ) is provided with a protecting, at least partly translucent, wear layer ( 2 ″) by for example spray coating, roller coating, curtain coating and immersion coating or by being provided with one or more sheets of α-cellulose impregnated with thermosetting resin or lacquer.

1 . A process for the manufacturing of surface elements ( 1 ) which comprises a decorative upper layer ( 2 ) and a supporting core ( 5 ), characterised in that; 
 i) a supporting core ( 5 ) with a desired format is manufactured and provided with an upper side ( 1 ′) and a lower side ( 4 ), whereby    ii) the upper side ( 1 ′) of the supporting core ( 5 ) is provided with a décor, by for example printing, which décor ( 2 ′) is positioned after a predetermined fixed point on the supporting core ( 5 ), whereby    iii) the upper side ( 1 ′) of the supporting core ( 5 ) is provided with a protecting, at least partly translucent, wear layer ( 2 ″) by for example spray coating, roller coating, curtain coating and immersion coating or by being provided with one or more sheets of α-cellulose impregnated with thermosetting resin or lacquer.    
     
     
         2 . A process according to  claim 1 , characterised in that the décor is achieved by digitisation of an actual archetype or by partly or completely being created in a digital media, which digitised décor ( 2 ′) is stored digitally in order to be used as a control function and original, together with possible control programs, when printing the décor ( 2 ′).  
     
     
         3 . A process according to  claim 2 , characterised in that at least parts of the digital décor ( 2 ′) is used, together with support programs for controlling further steps in the manufacturing procedure such as identification marking, packaging, lacquering, surface embossing, storing and delivery logistics as well as assembly instructions.  
     
     
         4 . A process according to any of the claims  1 - 3 , characterised in that the supporting core ( 5 ) is manufactured in the desired end user format and provided with edges ( 3 ) intended for joining before applying décor and wear layer.  
     
     
         5 . A process according to any of the claims  1 - 4 , characterised in that the main part of the supporting core ( 5 ) is constituted by a particle board or a fibre board.  
     
     
         6 . A process according to any of the claims  1 - 4 , characterised in that at least parts of the supporting core ( 5 ) is constituted of a polymer such as for example polyurethane or a polyolefin such as polyethylene, polypropylene or polybutene.  
     
     
         7 . A process according to  claim 6 , characterised in that the supporting core ( 5 ) except polymer also contains a filler in the form of a particle or fibre of organic or inorganic material.  
     
     
         8 . A process according to any of the claims  1 - 7 , characterised in that the translucent wear layer ( 2 ″) is constituted of a UV curing or electron beam curing resin or lacquer such as for example acrylic, epoxy or maleimide lacquer.  
     
     
         9 . A process according to  claim 8 , characterised in that the wear layer ( 2 ″) is applied in several steps with intermediate curing, of which the last is a a complete curing while the earlier are only partial.  
     
     
         10 . A process according to  claim 8  or  9 , characterised in that the wear layer ( 2 ″) also comprises hard particles with an average particle size in the range 50 nm -150 μm.  
     
     
         11 . A process according to  claim 10 , characterised in that the upper portion of the wear layer ( 2 ″) is provided with hard particles in the range 50 nm-30 μm, preferably 50 nm-10 μm while the inner portion of the wear layer ( 2 ″) is provided with hard particles in the range 10 μm-150 μm, preferably 30 μm-150 μm.  
     
     
         12 . A process according to  claim 10 , characterised in that the hard particles is constituted by silicon oxide, silicon carbide, α-aluminium oxide or the like.  
     
     
         13 . A process according to  claim 11 , characterised in that the hard particles is constituted by silicon oxide, silicon carbide, α-aluminium oxide, diamond or the like.  
     
     
         14 . A process according to any of the claims  1 - 7 , characterised in that the translucent wear layer ( 2 ″) is constituted by one or more sheets of α-cellulose impregnated with melamine-formaldehyde resin.  
     
     
         15 . A process according to  claim 14 , characterised in that the wear layer ( 2 ″) is joined with the supporting core ( 5 ) through heat and pressure, whereby the resin cures.  
     
     
         16 . A process according to  claim 14  or  15 , characterised in that the wear layer ( 2 ″) also comprises hard particles with an average particle size in the range 50 nm-150 μm.  
     
     
         17 . A process according to  claim 16 , characterised in that the upper portion of the wear layer ( 2 ″) is provided with hard particles in the range 50 nm-30 μm, preferably 50 nm-10 μm while the inner portion of the wear layer ( 2 ″) is provided with hard particles in the range 10 μm-150 μm, preferably 30 μm-150 μm.  
     
     
         18 . A process according to  claim 10 , characterised in that the hard particles is constituted by silicon oxide, silicon carbide, α-aluminium oxide or the like.  
     
     
         19 . A process according to  claim 11 , characterised in that the hard particles is constituted by silicon oxide, silicon carbide, α-aluminium oxide, diamond or the like.  
     
     
         20 . A process according to any of the claims  1 - 19 , characterised in that the décor on the surface elements ( 1 ) is constituted by a number of décor segments with intermediate borders, which borders, on at least two opposite edges of a surface element ( 1 ) coincides with borders on intended adjoining floor elements ( 1 ).  
     
     
         21 . A process according to any of the claims  1 - 20 , characterised in that at least one surface structured matrix which forms at least one surface structure segment is positioned on the decorative side of the surface element ( 1 ) during the step in the process where the wear layer ( 2 ″) is applied on the surface element ( 1 ) and is pressed towards this whereby the wear layer ( 2 ″) receives a surface with structure that enhances the realistic impression of the décor ( 2 ′).  
     
     
         22 . A process according to any of the claims  2 - 21 , characterised in that two or more surface structured matrixes, which each forms one surface structure segment, which segments are independent from each other concerning structure, and that said surface structure segments are intended to mainly, preferably completely coincide with corresponding pattern segments in the décor, is thoroughly positioned on the decorative side of the surface element ( 1 ) during the steps in the process where the wear layer ( 2 ″) is provided with a wear layer ( 2 ″), and pressed toward this whereby the wear layer ( 2 ″) receives a surface structure ( 2 ′″) corresponding to the different pattern segments in the décor.  
     
     
         23 . A process according to  claim 21  or  22 , characterised in that one or more matrixes forms the structured surface of one or more rollers whereby the surface element ( 1 ) is passed between the structured roller and matching counter stay under continuos or discontinuous pressure between the rollers and the counter stays.  
     
     
         24 . A process according to  claim 23 , characterised in that rollers equipped with two or more matrixes has a circumference adapted to repetition distance in the variation of direction in the décor.  
     
     
         25 . A process according to  claim 22 , characterised in that one or more matrixes forms the structured surface on one or more press belts, whereby the surface element ( 1 ) is passed between the press belts and counter stays, with the decorative side facing the press belts, during continuous or discontinuous pressure between the press belts and counter stays.  
     
     
         26 . A process according to  claim 22 , characterised in that one or more matrixes forms the structured surface on one or more static moulds which momentary and static is pressed towards the decorative surface of the surface element ( 1 ).  
     
     
         27 . A process according to any of the claims  21 - 26 , characterised in that specially characteristic décor segments such as borderlines between simulated slabs, bars, blocks or the like and also knots, cracks, flaws and grain which is visually simulated in the décor ( 2 ′), is stored as digital data, that said data is used for guiding automated engraving or pressing tools when providing said characteristic décor segments with a suitable surface structure, and that said engraving tool or pressing tool is synchronised via the predetermined fixing point on the surface element ( 1 ).  
     
     
         28 . A surface element ( 1 ) manufactured according to any of the claims  1 - 27 , characterised in that they form floor elements intended to be joined to become a floor covering material, wall elements intended to be joined to become a wall covering material or ceiling elements intended to be joined to become a ceiling material.