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CN1201059C - 一种用来制造表面元件的方法 - Google Patents

一种用来制造表面元件的方法 Download PDF

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Publication number
CN1201059C
CN1201059C CNB008185816A CN00818581A CN1201059C CN 1201059 C CN1201059 C CN 1201059C CN B008185816 A CNB008185816 A CN B008185816A CN 00818581 A CN00818581 A CN 00818581A CN 1201059 C CN1201059 C CN 1201059C
Authority
CN
China
Prior art keywords
decoration
wearing layer
varnish
layer
grit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CNB008185816A
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English (en)
Other versions
CN1425098A (zh
Inventor
克里斯特·汉森
约汉·伦德格林
哈坎·威纳尔森
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin Nordic AB
Original Assignee
Perstorp Flooring AB
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Filing date
Publication date
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Application filed by Perstorp Flooring AB filed Critical Perstorp Flooring AB
Publication of CN1425098A publication Critical patent/CN1425098A/zh
Application granted granted Critical
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Classifications

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    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/21—Ink jet for multi-colour printing
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Abstract

一种用来制造包括一个上部装饰和一个支撑芯部的表面元件的方法，其特征在于包括如下步骤：i)制造具有希望形式的支撑芯部，并且提供有一个上侧和一个下侧，ii)支撑芯部的上侧通过打印提供有一种装饰，装饰在一个预定固定点之后定位在支撑芯部上，iii)支撑芯部的上侧通过例如喷涂、滚涂、幕式淋涂及浸涂；或通过提供有用热固树脂或清漆浸渍的一块或多块α纤维素板，提供有一个防护性的、至少部分透明的耐磨层。

Description

一种用来制造表面元件的方法
技术领域
本发明涉及一种用来制造带有一个装饰上表面的表面元件的方法，其中装饰元件在相邻表面元件之间具有显著改进的装饰匹配。
背景技术
覆盖有热固叠层的制品当今在许多领域是常见的。他们大多用在对抗磨性要求较高的场合，并且此外用在希望耐化学材料和潮湿的场合。作为这种制品的例子，能提及地板、踢脚板、桌面，工作台面及护墙板。
热固叠层最经常地包括多块底板，使装饰板最靠近表面放置。装饰板能提供有希望的图案。常见的图案通常具体化不同种类的木材或诸如大理石和花岗岩之类的矿石。
在地板元件上一种常见图案是杆式图案，其中在装饰中模仿两行或多行例如木杆。
传统热固叠层制造包括多个步骤，这些步骤将导致高达±5mm的随机匹配公差，认为这很大。包括在叠层地板制造中的步骤是：把装饰打印在α纤维素纸上；把装饰纸用三聚氰氨-甲醛树脂浸渍；干燥装饰纸；把装饰纸在热量和压力下与类似处理的支撑纸层压在一起；把装饰叠层涂敷在载体上；及最后把载体锯成和切削成希望的样式。在制造时的所有这些步骤将导致装饰纸上样式的变化。因此实际上不可能在元件之间实现希望的图案匹配，而不引起大量的叠层浪费。热固叠层是叠层地板颇为昂贵的部分。
发明内容
通过本发明使得有可能克服上述问题，并且得到一种带有装饰表面的表面元件，其中在不同表面元件之间的装饰图案相匹配。本发明设计一种用来制造包括一个上部装饰和一个支撑芯部的表面元件的方法。表面元件可以用作地板、墙板或天花板。本发明的特征在于：
i)制造具有希望形式的支撑芯部，并且提供有一个上侧和一个下侧，
ii)支撑芯部的上侧通过打印提供有一种装饰，装饰在一个预定固定点之后定位在支撑芯部上，
iii)支撑芯部的上侧通过例如喷涂、滚涂、幕式淋涂及浸涂；或通过提供有用热固树脂或清漆浸渍的一块或多块α纤维素板，提供有一个防护性的、至少部分透明的耐磨层。
装饰通过实际原型的数字化或在数字介质中部分或完全创建而实现，当打印装饰时，把装饰与可能的控制程序一起数字化存储，以便用作控制功能和正本。
装饰因而可以通过形成希望装饰的高分辨率或选择分辨率的数字画面得到。这借助于数字摄像机或扫描仪适当地进行。最常见的装饰当然是不同种类的木材和像大理石之类的矿石，因为这些可能继续是在家庭和公共环境中希望的表面装饰。然而，有可能描绘可见的任何东西。然后编辑层的数字化型式，以适合支撑芯部的尺寸。也有可能把装饰以多种不同形式，像改变色调、对比度、把装饰划分成较小段及添加其它装饰元件，重新排列装饰。也有可能在为图形设计装备的计算机中完全创建装饰。有可能把模拟装饰创建得如此真实，以致于即使专业人员用肉眼把它与真正的材料区分开也有很大问题。这使得有可能制造例如具有稀有种类木材，像黑檀或蔷薇木，的几乎完美错觉的地板，而仍保护树木免受灭绝的威胁。
数字化装饰与指导程序一起用来控制打印机。打印机可以是静电型或喷墨型打印机。最经常的颜色-黄色、深红色、蓝绿色及墨色对于打印过程是足够的，但在某些情况下，添加白色可能是便利的。一些颜色使用颜色-黄色、深红色、蓝绿色、墨色及白色难以实现，由此可以添加颜色-浅深红色和浅蓝绿色。在特定色调难以实现的场合或在仅希望色谱某些部分具有相互混合阴影的场合，也有可能添加所谓的斑点颜色。需要的分辨率大多取决于要模拟的装饰，但10-1500点每英寸(dpi)的分辨率是其中打印大多数装饰的实用范围。在通常条件下，300-800dpi的分辨率在创建即使非常复杂的装饰图案的模拟时也足够了，并且仍实现一种不用密切和彻底检查用肉眼非常难以与原型分开的结果。
当指导在制造过程中的其它操作和过程时，数字存储的装饰也能与支持程序一起使用。在操作中的这样的步骤可以包括像标识标记、包装、涂漆、表面压纹、存储和传送逻辑以及装配指令的过程。
便利的是，以希望的最终用户样式制造支撑芯部，并且在涂敷装饰和耐磨层之前给它装有适于接合的边缘，因为由此根本上减小浪费量。装饰匹配公差也将通过这种过程进一步改进。
支撑芯部的主要部分适当地由刨花板或纤维板构成。然而，有可能制造至少部分包括像例如聚氨基甲酸酯之类的聚合物、或诸如聚乙烯、聚丙烯或聚丁烯之类的聚烯烃的芯部。基于聚合物的芯部能通过注模或压模实现，并且通过塑性模压能给出其形状，并因此不需要任何研磨处理。基于聚合物的芯部除聚合物外也可以包含有机或无机材料的颗粒或纤维形式的填充物，这除使用之外一种成本减小材料也用来改进芯部的机械特性。作为这样的适当填充物的一个例子，能提及：纤维素或木屑、秸秆、淀粉、玻璃、石灰、滑石、石粉及沙子。可以改变的机械特性是例如粘度、热膨胀系数、弹性、密度、耐火性、吸湿能力、声学性质、导热性、弯曲和剪切强度以及软化温度。
上表面，即装有装饰的表面，在打印之前适当地表面处理。这样的表面处理然后包括在步骤-底涂敷和放置，的至少一个中。也能可能把表面装有与要涂敷的装饰相匹配的结构。
透明耐磨层适当地由紫外线或电子束熟化清漆，如丙烯酸、环氧、或马来酰亚胺清漆，构成。耐磨层分几步借助于中间熟化涂敷，其中最后一步是完全熟化，而较早的仅是部分熟化。由此有可能实现厚平面层。耐磨层适当地包括平均颗粒尺寸在50nm-150μm范围内的硬颗粒。在10μm-150μm范围内，且最好在30μm-15μm范围内的较大颗粒最先用来实现抗磨性，而在50nm-30μm范围内，最好为50nm-10μm，的较小颗粒用来实现耐擦伤性。较小颗粒因此最靠近表面使用，而较大颗粒分布在耐磨层中。硬颗粒适当地由碳化硅、氧化硅、α氧化铝等构成。抗磨性由此显著增大。在30mm-150mm范围内的颗粒能例如喷撒在仍然湿润的清漆上，从而它们至少部分嵌在完成的耐磨层中。因此适当地分几步借助于中间喷撒站涂敷耐磨层，其中把颗粒添加表面上。此后能熟化耐磨层。也有可能把通常颗粒尺寸在30μm以下的较小颗粒与标准清漆混合。如果胶凝剂等存在，则可以添加较大颗粒。带有较小颗粒的清漆适当地用作顶部涂层，较靠近上表面。通过把在50nm-1000nm范围内的非常小颗粒喷撒在最上部清漆层中，能改进耐擦伤性。而且，这些所谓的纳米颗粒能与涂敷在具有高颗粒含量的薄层中的清漆相混合。这些纳米颗粒除碳化硅、氧化硅及α氧化铝之外也可以由金刚石构成。
根据本发明的一个实施例，透明耐磨层由浸渍有三聚氰氨-甲醛树脂的一块或多块α纤维素板构成。这些板在热量和压力下与芯部接合，由此树脂熟化。而且在该实施例中，有可能添加平均颗粒尺寸在50nm-150μm范围内的硬颗粒。在10μm-150μm范围内，最好为30μm-150μm，的较大颗粒最先用来实现抗磨性，而在50nm-30μm范围内，最好为50nm-10μm，的较小颗粒用来实现耐擦伤性。较小颗粒因此用在顶部表面上，或者非常靠近其使用，而较大颗粒可以分布在耐磨层中。而且这里颗粒便利地由碳化硅、氧化硅、α氧化铝、金刚石等构成，其中由于成本原因金刚石仅用作小于1μm的颗粒。α纤维素板由此在带有两个钢带的连续压带机中与表面元件的其余部分适当地压在一起。在压力机中的压力由此适当地是5-100巴，最好是20-80巴。温度适当地在140-200℃的范围内，最好是160-180℃。也有可能利用一种不连续过程，其中多个表面元件能在所谓的多开口压力机中同时压制。压力那么通常是20-150巴，最好是70-120巴，而温度适当地是120-180℃，最好是140-160℃。
在表面元件上的装饰适当地由带有中间边界的多个装饰段构成，这些边界在至少两个相对边缘上与预定的相邻表面元件重合。
也希望把表面元件装有打算增强表面元件装饰的真实性的表面结构。这通过在与耐磨层涂敷连接的表面元件装饰表面上的一个对应装饰段或多个装饰段上，定位至少一种表面结构基材、形成至少一个表面结构段适当地实现。把这种基材压向耐磨层，由此这将收到一种具有增强装饰真实性的结构的表面。
当模拟更复杂的图案，像木块人字形图案或具有两个或多个分散和定向装饰的其它装饰时，适当地使用每个形成一个结构段的至少两种结构基材。结构段在这里从结构观点看是彼此独立的。表面结构段打算至少部分但最好完全地与装饰的对应装饰段相匹配。表面结构段准确地定位在与耐磨层的涂敷连接的表面元件的装饰侧，并且压在其上，由此耐磨层提供有一种其中结构定向与装饰的不同方向相对应的表面结构。
一种或多种基材最好形成一个或多个轧辊的表面。表面元件然后在轧辊与相对静止轧辊之间通过，使装饰侧面对着结构轧辊。结构轧辊连续或不连续地压向表面元件的装饰表面。
包含两种或多种基材的轧辊适当地提供有适应装饰方向的重复变化频率的圆周。
也有可能把结构基材涂敷在压制带的表面上。表面元件然后在压制带与相对静止的压制带之间、在结构压制带与相对静止的压制带之间的连续或不连续压力下通过。
根据一个可选择过程，有可能使一种或多种基材形成一个或多个静止模具的结构表面，该结构表面瞬时压向表面元件的装饰侧。
根据本发明的一个实施例，具体特征装饰段，如在模拟板、条、块等之间的边界线还有节、裂纹、裂痕及在装饰中视觉模拟的纹理，作为数字数据存储。当所述特征装饰段提供有适当的表面结构时，所述数据用来指导自动雕刻或压制工具，并且该所述雕刻或压制工具通过在表面元件上的预定固定点同步。
在本申请中描述的、用来制造表面元件的过程从逻辑观点看是非常便利的，因为根本上减小在实现新装饰时的步骤数量。根据本发明，有可能通过使用喷墨打印机或照相复印机，使用数字创建或存储数据来把装饰直接打印在表面元件上。所谓的准备时间因此将非常短，由此即使非常特殊的客户要求也可以以合理成本满足。根据本发明有可能把例如在大量表面元件上伸展的非常大样式的世界地图主要制造到与批量生产的表面元件相同的成本。由于可以把装饰一直数字处理到涂敷到装饰表面上的点，所以准备时间实际上是不存在的，而同时高度自动化是可实用的。也有可能自动地把表面元件提供有标识和定向标记，这使得复杂装饰，像以上例子中的世界地图，的建立容易得多。这至今是不可能的。
表面元件上的装饰可以按如下处理：
i)选择区段图案，区段在每个表面元件上包括至少两个装饰段。从上方所看到的表面元件的形状因此从组：三角形、方形、矩形、七边形、五边形及八边形选择，而段的形状从组-三角形、方形、矩形、七边形、五边形、八边形、圆形、椭圆形、扰动及不规则形选择。
ii)然后对于每个段选择一种段装饰。段装饰从组：不同种类的木材、矿石和石头；不同种类的织物、艺术作品和基于抽象图案的装饰的数字化和模拟描绘选择。
iii)在其中选择出自数据库的终端上进行每种选择，并且通过终端具体化该选择。
装饰最好通过实际原型的数字化或在数字介质中部分或完全创建实现。当打印装饰时，最好把数字化装饰与控制程序和选择参数一起数字化存储，以便用作控制功能和正本。
把要由表面元件覆盖的表面尺寸适当地输入到终端中，并且支持程序计算一种建立图案。建立图案计算也适当地用来打印组装指令。为了具体化该选择，建立图案计算能用来打印带有选择图案和装饰的计算建立的小型化拷贝。把要由表面元件覆盖的表面尺寸适当地输入到终端中，并且支持程序进一步计算在表面元件之间的装饰和区段图案匹配。
选择最好也与支持程序一起用来控制在从组：标识标记、定位标记、包装、涂膝、表面压纹、存储和传送逻辑选择的制造过程中的另外步骤。
一种算法适于用来指导装饰段和区段图案的定位，从而来自一个表面元件的装饰段可以在接合表面元件上连续。控制程序适于与装饰数据和选择参数一起用来把匹配标识涂敷在表面元件上。
按上述制造的表面元件适于用作地板覆盖材料，其中对稳定性和抗擦伤性及耐磨性要求较高。根据本发明也有可能把表面元件用作墙壁或天花板装饰材料。然而在后两种情况下不必涂敷厚耐磨层覆盖，因为在这样的表面上直接磨损几乎不发生。
联系包括的附图、实施例子及表示本发明不同实施例的示意过程描述，进一步描述本发明。
附图说明
图1表示一种表面元件1的各部分。
具体实施方式
因而，附图表示一种表面元件1的诸部分，表面元件1包括一个上部装饰2、打算用来接合的边缘3、一个下侧4及一个支撑芯部5。该过程通过制造具有希望样式和打算用来接合的边缘3的支撑芯部5开始。支撑芯部5进一步提供有一个适于打印的上侧1′和一个下侧4。支撑芯部5的上侧1′然后提供有通过利用喷墨打印机打印的装饰2′。装饰2′跟随支撑芯部5上的一个预定固定点定向。支撑芯部5的上侧1′然后通过幕式淋涂提供有一个保护透明耐磨层2″。支撑芯部5由刨花板或纤维板构成。透明耐磨层2″由紫外线熟化丙烯酸清漆构成，该清漆分几步借助于中间熟化涂敷，其中最后一步是完全熟化，而较早步骤仅是部分熟化。耐磨层2″也包括平均颗粒尺寸在0.5μm-150μm范围内的α氧化铝硬颗粒。
在丙烯酸清漆的最终熟化之前，把表面结构基材向表面元件1的装饰侧定位和压制，由此耐磨层2″的表面接收增强装饰2′的真实性的一种表面结构2。
也有可能利用两种或多种表面结构基材，每种形成一个结构段，在其之间结构是独立的，这使得有可能模拟例如木块人字形图案装饰的表面结构。
过程方案1
基于支撑聚合物填充物的芯部以希望样式制造，并且提供有上侧、下侧及提供有诸如舌状物和槽之类的接合件的边缘。支撑芯部的上侧然后用砂纸磨光，此后涂敷底膝。然后借助于数字照相五色打印机把装饰涂敷在上侧上。颜色是深红色、黄色、蓝绿色、白色及黑色。装饰以支撑芯部角部的形式离开一个预定固定点定位，而装饰方向与从相同角部开始的长侧边缘对齐。
用于装饰的基本数据作为数字数据存储。该数字数据已经通过用数字摄像机数字化多种木材纹理图案获得。选择多个具有固定宽度、但具有变化长度的矩形块，并且与数字木材纹理画面分开。选择矩形块的宽度，从而三个块宽度等于支撑芯部的宽度。木块的数字图像然后跟随木材纹理图案和颜色分类，从而获得多组。这些组是：具有均匀纹理的清楚木材、具有均匀纹理的深色木材、具有节和裂痕的清楚木材、具有节和裂痕的深色木材、清楚交叉纹理的木材及最后深色交叉纹理的木材。每组包含五种不同的块模拟。一种算法供给到用来指导打印操作的计算机中，从而模拟木块分三个经度行数字放置，并且混合，从而两个类似木块绝不会彼此相邻放置。该算法也指导在模拟木块之间的纬度边界线的位置，从而它们在相邻行之间以多于一个块宽度错开。它也指导边界线的纬度位置，从而它或者与支撑芯部的较短边缘对齐，或者以多于一个块宽度错开。也由计算机指导的另一个打印机用来把一个伸展匹配数码打印在下侧短边边缘上。装饰因此在表面元件上在径度方向上连续，并且当按编号顺序放置表面元件时得到一种完美的匹配。
然后借助于轧辊涂敷紫外线熟化丙烯酸清漆的底层。然后把平均颗粒尺寸在150μm范围内的颗粒喷撒到仍然湿润的底层上，由此通过喷涂涂敷紫外线熟化丙烯酸清漆的主层。然后使用紫外线光部分熟化两层清漆，由此清漆的粘度增大。然后借助于轧辊涂敷具有2μm平均尺寸的硬颗粒形式的添加剂的紫外线熟化丙烯酸清漆的顶部层。然后把100nm平均尺寸的硬颗粒喷撒在湿润顶部层的顶部上，由此用紫外线光部分熟化清漆，从而粘度增大。仍然软的清漆然后提供有窄、小、细长凹槽形式的结构，模拟木材的微孔。这将增强装饰的真实性。这通过在每行模拟木块的两个不同结构轧辊之间的交替实现。轧辊的结构分别模拟均匀木材纹理和交叉纹理木材。轧辊交替地压向清漆表面，同时清漆表面通过。轧辊的定位通过用来打印装饰的数字存储数据以及这里使用的固定点指导。
根据一个选择实施例，有可能利用具有瞬时压向装饰侧的表面结构的一个或多个静止模具。
具体特征装饰段，如在板、条、块等之间的边界线还有节、裂纹、裂痕及在装饰中视觉模拟的纹理，适于作为数字数据存储。该数据通过处理模拟木材块的选择部分获得，从而获得指导数据。所述数据然后用来指导装有雕刻工具或压制模具的自动机器人，该自动机器人提供具有匹配所述特征装饰段的结构的清漆表面。该操作在这里也通过在支撑芯部上的预定固定点同步。
清漆然后用紫外线光完全熟化到希望强度，由此完成的表面元件可以用肉眼或由计算机支持的数字摄像机检查。表面元件然后分批包装，并且提供有标识标记。
以上过程使得有可能具有完全客户驱动的制造，其中即使非常小的量也可以以与大批制造相同的效率生产。尽管联系以上过程方案仅描述了一种装饰，但对于熟悉本技术的任何人显然，在过程中能非常容易地改变装饰。所有制造的重要步骤，如打印、结构化、检查、包装及标识标记，可以由中央处理数据控制和管理。这使得在逻辑上有可能制造客户设计的装饰。这样一种过程举例如下：
客户通过因特网或在地方零售商处利用数据库。也有可能另一个操作者利用数据库。数据库包含样本和/或大量标准装饰的减小分辨率拷贝，这些能跟随预定参数相组合。
参数例如可以涉及单个表面元件，其中例如人字形图案、金刚石图案及块图案可以是装饰区段的选择。这里也有可能随机地或通过选择参数填充段，例如大理石、桦木及红木，选择一组不同的模拟。客户也可以把来自数字化和处理的他自己的设计的里层添加到希望样式和分辨率。
参数可以可选择地包括要求几个表面元件空间的装饰段，例如整个世界的地图。参数这里可以进一步包括较大设计到周围装饰的淡化、其它装饰的周围框架等。
客户输入要由表面元件覆盖的表面测量。客户然后进行来自数据库的选择，并且能够作为一个完整的表面、或在屏幕上或通过打印看到他的选择。使用的具体化程序也适于用来计算建立图案和在表面元件上呈现带有标识号码的建立指令，并且在这里切开元件以便进行完美匹配。表面元件在装饰侧上也提供有可除去的匹配线，使相邻行之间的装饰匹配更容易。客户或零售商可以通过电子邮件确认他的订单，其中把图案和装饰减化成一个代码序列，并且订单能是对于指导上述制造过程的计算机的直接输入。客户和/或零售商数据跟随制造过程一直到包装，并且实现一种完全客户指导的制造过程。
过程方案2
Figure C0081858100161
基于支撑纤维板的芯部以希望样式制造，并且提供有上侧、下侧及边缘。支撑芯部的上侧然后用砂纸磨光，此后涂敷白色底膝。然后借助于数字喷墨四色打印机把装饰涂敷在上侧上。颜色是深红色、黄色、蓝绿色及黑色。装饰以支撑芯部角部的形式离开一个预定固定点定位，而装饰方向与从相同角部开始的长侧边缘对齐。
用于装饰的基本数据作为数字数据存储。该数字数据已经通过用数字摄像机数字化多种木材纹理图案获得。选择多个具有固定宽度、但具有变化长度的矩形块，并且与数字木材纹理画面分开。选择矩形块的宽度，从而三个块宽度等于完成支撑芯部的宽度。木块的数字图像然后数字接合，以形成例如200×1200mm的特定尺寸的矩形表面。不同块的这种组合的选择量按上述设计，从而获得多个稍微不同的矩形表面。打印机或最好是一组打印机如此定位，从而具有特定中间距离的希望数量的矩形装饰表面打印在支撑芯部上。在矩形表面之间的中间距离是用来分开和模压边缘需要的距离。装饰打印机也用来把固定点打印在预定位置处。也由计算机指导的另一个打印机用来把标识代码打印在每个打算完成的表面元件的下侧上。
然后借助于轧辊涂敷紫外线熟化丙烯酸清漆的底层。然后把平均颗粒尺寸在75μm范围内的颗粒喷撒到仍然湿润的底层上，由此借助于轧辊涂敷具有2μm平均尺寸的硬颗粒形式的添加剂的紫外线熟化丙烯酸清漆的顶部层。然后把100nm平均尺寸的硬颗粒喷撒在湿润顶部层的顶部上，由此用紫外线光部分熟化清漆，从而粘度增大。仍然软的清漆然后提供有窄、小、细长凹槽形式的结构，模拟木材的微孔。这将增强装饰的真实性。这通过把轧辊压向清漆表面实现，同时清漆表面通过。当希望与过程方案1一起描述的更复杂和完全匹配的表面结构时，轧辊的定位通过用来打印装饰的数字存储数据、以及这里使用的固定点指导。
清漆然后用紫外线光完全熟化到希望强度，由此把完成的表面元件切成预定样式，装有具有接合功能、由铣削模压的边缘。切削和边缘模压过程离开靠近装饰打印的固定点定位。表面元件然后可以用肉眼或由计算机支持的数字摄像机检查。表面元件然后分批包装，并且提供有标识标记。
根据该过程中的一个可选择工序，有可能在过程的较早阶段切削和模压边缘。适于涂敷和熟化在打印装饰顶部上的清漆保护层，随后是边缘的切削和模压。然后涂敷耐磨层的剩余和主要部分，如联系以上过程方案1或2描述的那样。
以上过程使得有可能具有一种用户开始的制造，其中即使非常小的量也可以以与大批制造相同的效率生产。尽管联系以上过程方案仅描述了一种装饰，但对于熟悉本技术的任何人显然，在过程中能非常容易地改变装饰。所有制造的重要步骤，如打印、结构化、检查、包装及标识标记，可以由中央处理数据控制和管理。
本发明也通过实施例子描述。
例1
把中密度纤维板的支撑芯部用砂纸磨平。把一层底膝涂敷在纤维板的顶部上。在把装饰打印在底层的顶部上之后熟化底层。
然后通过借助于滚涂涂敷30g/m2的紫外线熟化丙烯酸清漆开始耐磨层的建立。把20g/m2的由α氧化铝制成的、具有70μm平均颗粒尺寸的硬颗粒喷撒在仍然粘的清漆上。然后把清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。然后把另一层30g/m2的紫外线熟化丙烯酸清漆滚涂到已经涂敷的层上，此后把另一层20g/m2的70μm平均颗粒尺寸的α氧化铝颗粒喷撒在仍然粘的第二涂层上。然后把清漆暴露于预定能量的紫外线光，从而它仅部分熟化并且粘度增大。然后如以上那样借助于中间部分熟化通过滚涂涂敷三层紫外线熟化丙烯酸清漆。三层的每层具有20g/m2的表面重量。在涂敷三层之后，硬颗粒完全嵌在清漆中，并且获得一个平面上部耐磨层表面。
然后开始顶部涂敷工序。紫外线熟化丙烯酸面涂层清漆的一个第一层借助于一个滚涂器涂敷在以前、部分熟化层的顶部上。面涂层清漆包含重量10％的10μm平均颗粒尺寸的α氧化铝硬颗粒。第一层涂敷到10g/m2的表面重量。然后把面涂层清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。然后涂敷面涂层清漆的一个第二层，并且如上述那样部分熟化。耐磨层然后借助于表面结构轧辊提供有一种表面结构。然后把面涂层成分的一个第三层涂敷在结构耐磨层的顶部上。面涂层的第三层也涂敷到10g/m2的表面重量。然后把耐磨层暴露于预定能量量的紫外线光，从而它完全熟化。
然后根据ISO 4586/2-88测定耐磨层的抗磨性，其中得到7100圈的IP值。7100圈的IP值对于具有像旅馆前厅、过道等的中等至大流量交通的地板覆盖材料完全足够。
例2
把中密度纤维板的支撑芯部用砂纸磨平。把一层底膝涂敷在纤维板的顶部上。在把装饰打印在底层的顶部上之后熟化底层。然后通过借助于滚涂涂敷30g/m2的紫外线熟化丙烯酸清漆开始耐磨层的建立。把20g/m2的由α氧化铝制成的、具有70μm平均颗粒尺寸的硬颗粒喷撒在仍然粘的清漆上。然后把清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。然后把另一层30g/m2的紫外线熟化丙烯酸清漆滚涂到已经涂敷的层上，此后把另一层20g/m2的70μm平均颗粒尺寸的α氧化铝颗粒喷撒在仍然粘的第二涂层上。然后把清漆暴露于预定能量的紫外线光，从而它仅部分熟化并且粘度增大。然后如以上那样借助于中间部分熟化通过滚涂涂敷三层紫外线熟化丙烯酸清漆。三层的每层具有20g/m2的表面重量。在涂敷三层之后，硬颗粒完全嵌在清漆中，并且获得一个平面上部耐磨层表面。而且把三层清漆的最上部熟化到希望粘度。
然后把第二装饰打印在耐磨层的顶部上。定向和定位与最靠近芯部的第一装饰相同的第二装饰，从而它完全与第一装饰匹配。
然后通过借助于滚涂涂敷30g/m2的紫外线熟化丙烯酸清漆开始一个上部耐磨层的建立。把20g/m2的由α氧化铝制成的、具有70μm平均颗粒尺寸的硬颗粒喷撒在仍然粘的清漆上。然后把清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。然后把另一层30g/m2的紫外线熟化丙烯酸清漆滚涂到已经涂敷的层上，此后把另一层20g/m2的70μm平均颗粒尺寸的α氧化铝颗粒喷撒在仍然粘的第二涂层上。然后把清漆暴露于预定能量的紫外线光，从而它仅部分熟化并且粘度增大。然后如以上那样借助于中间部分熟化通过滚涂涂敷三层紫外线熟化丙烯酸清漆。三层的每层具有20g/m2的表面重量。在涂敷三层之后，硬颗粒完全嵌在清漆中，并且获得一个平面上部耐磨层表面。
然后开始顶部涂敷工序。紫外线熟化丙烯酸面涂层清漆的一个第一层借助于一个滚涂器涂敷在以前、部分熟化层的顶部上。面涂层清漆包含重量10％的10μm平均颗粒尺寸的α氧化铝硬颗粒。第一层涂敷到10g/m2的表面重量。然后把面涂层清漆暴露于预定能量量的UV光，从而它仅部分熟化并且粘度增大。然后涂敷面涂层清漆的一个第二层，并且如上述那样部分熟化。耐磨层然后借助于表面结构轧辊提供有一种表面结构。然后把面涂层成分的一个第三层涂敷在结构耐磨层的顶部上。面涂层的第三层也涂敷到10g/m2的表面重量。然后把耐磨层暴露于预定能量量的紫外线光，从而它完全熟化。
然后根据ISO 4586/2-88测定耐磨层的抗磨性，其中得到13500圈的IP值。13500圈的IP值对于具有像机场、火车站等的大流量交通的地板覆盖材料完全足够。装饰和耐磨层的第二层将增加抗磨性，而不会得到在装饰中的多余模糊效果。
例3
把中密度纤维板的支撑芯部用砂纸磨平。把一层底膝涂敷在纤维板的顶部上。在把装饰打印在底层的顶部上之后熟化底层。
然后通过借助于滚涂涂敷15g/m2的紫外线熟化丙烯酸清漆开始耐磨层的建立。把20g/m2的由α氧化铝制成的、具有70μm平均颗粒尺寸的硬颗粒喷撒在仍然粘的清漆上。然后把清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。然后按以上那样通过滚涂涂敷一层紫外线熟化丙烯酸清漆，并且部分熟化。该层具有40g/m2的表面重量。在涂敷清漆层之后，硬颗粒完全嵌在清漆中，并且获得一个主要平面的上部耐磨层表面。
然后开始顶部涂敷工序。紫外线熟化丙烯酸清漆的一个第一层借助于一个滚涂器涂敷在以前、部分熟化层的顶部上。面涂层清漆包含重量10％的10μm平均颗粒尺寸的α氧化铝硬颗粒。第一层涂敷到10g/m2的表面重量。然后把面涂层清漆暴露于预定能量量的紫外线光，从而它仅部分熟化并且粘度增大。耐磨层然后借助于表面结构轧辊提供有一种表面结构。然后把面涂层成分的一个第二、最终层涂敷在结构耐磨层的顶部上。面涂层的第二层也涂敷到10g/m2的表面重量。然后把耐磨层暴露于预定能量量的紫外线光，从而它完全熟化。
然后根据ISO 4586/2-88测定耐磨层的抗磨性，其中得到3100圈的IP值。3100圈的IP值对于具有像卧室、起居室等小流量交通的地板覆盖材料完全足够。
本发明不限于表示的实施例，因为这些在本发明的范围内能以不同方式变化。例如代之以在联系过程方案1描述的过程中、和特别是在联系过程方案2描述的过程中的丙烯酸清漆，有可能使用用热固树脂浸渍的所谓α纤维素覆盖板。用三聚氰氨-甲醛树脂浸渍的这些α纤维素板通过加热和压力与支撑芯部接合，由此树脂熟化。抗磨性在该实施例中也可以通过把在范围50nm-150μm范围内的硬颗粒添加到耐磨层而提高。

Claims (27)

1.一种用来制造包括一个上部装饰(2)和一个支撑芯部(5)的表面元件(1)的方法，其特征在于包括如下步骤：
i)制造具有希望形式的支撑芯部(5)，并且提供有一个上侧(1′)和一个下侧(4)，
ii)支撑芯部(5)的上侧(1′)通过打印提供有一种装饰，装饰(2′)在一个预定固定点之后定位在支撑芯部(5)上，
iii)支撑芯部(5)的上侧(1′)通过从包括喷涂、滚涂、幕式淋涂及浸涂的组中选出的一种方法，或通过提供有用热固树脂或清漆浸渍的一块或多块α纤维素板，提供有一个防护性的、至少部分透明的耐磨层(2″)。
2.根据权利要求1所述的方法，其特征在于，装饰通过实际原型的数字化或在数字介质中部分或完全创建而实现，当打印装饰(2′)时，把装饰(2′)与可能的控制程序一起数字化存储，以便用作控制功能和正本。
3.根据权利要求2所述的方法，其特征在于，至少部分数字装饰(2′)与支持程序一起使用，这些支持程序用来控制在制造工序中的另外步骤，该另外步骤是从以下组中选择的：标识标记、包装、涂漆、表面压纹、存储和传送逻辑以及装配指令。
4.根据权利要求1-3任一项所述的方法，其特征在于，支撑芯部(5)以希望的最终用户形式制造，并且在涂敷装饰和耐磨层之前提供有打算用来接合的边缘(3)。
5.根据权利要求1所述的方法，其特征在于，支撑芯部(5)的主要部分由刨花板或纤维板构成。
6.根据权利要求1所述的方法，其特征在于，至少部分支撑芯部(5)由聚合物：聚氨基甲酸酯、或聚烯烃：聚乙烯、聚丙烯或聚丁烯构成。
7.根据权利要求6所述的方法，其特征在于，支撑芯部(5)除聚合物之外还包含有机或无机材料的颗粒或纤堆形式的填充物。
8.根据权利要求1所述的方法，其特征在于，透明耐磨层(2″)由紫外线熟化树脂或清漆或者电子束熟化树脂或清漆丙烯酸、环氧、或马来酰亚胺清漆构成。
9.根据权利要求8所述的方法，其特征在于，耐磨层(2″)分几步借助于中间熟化涂敷，其中最后是完全熟化，而较早仅是部分熟化。
10.根据权利要求9所述的方法，其特征在于，耐磨层(2″)也包括平均颗粒尺寸在50nm-150μm范围内的硬颗粒。
11.根据权利要求10所述的方法，其特征在于，耐磨层(2″)的上部提供有在范围50nm-30μm内的硬颗粒，而耐磨层(2″)的内部提供有在范围10μm-150μm内的硬颗粒。
12.根据权利要求10所述的方法，其特征在于，硬颗粒由碳化硅、氧化硅、α氧化铝构成。
13.根据权利要求11所述的方法，其特征在于，硬颗粒由碳化硅、氧化硅、α氧化铝、金刚石构成。
14.根据权利要求1所述的方法，其特征在于，透明耐磨层(2″)由用三聚氰氨-甲醛树脂浸渍的一块或多块α纤维素板构成。
15.根据权利要求14所述的方法，其特征在于，耐磨层(2″)与支撑芯部(5)通过热量和压力接合，由此树脂熟化。
16.根据权利要求15所述的方法，其特征在于，耐磨层(2″)也包括平均颗粒尺寸在50nm-150μm范围内的硬颗粒。
17.根据权利要求16所述的方法，其特征在于，耐磨层(2″)的上部提供有在范围50nm-30μm内的硬颗粒，而耐磨层(2″)的内部提供有在范围10μm-150μm内的硬颗粒。
18.根据权利要求16所述的方法，其特征在于，硬颗粒由碳化硅、氧化硅、α氧化铝构成。
19.根据权利要求17所述的方法，其特征在于，硬颗粒由碳化硅、氧化硅、α氧化铝、金刚石构成。
20.根据权利要求2所述的方法，其特征在于，在表面元件(1)上的装饰由带有中间边界的多个装饰段构成，这些边界在一个表面元件(1)的至少两个相对边缘上与打算接合的地板元件(1)的边界重合。
21.根据权利要求1所述的方法，其特征在于，对于涂敷耐磨层(2″)，把形成至少一个表面结构段的至少一种表面结构基材定位在表面元件(1)的装饰表面上并且压向该装饰表面，由此耐磨层(2″)接收一个表面，该表面具有增强装饰(2′)的真实性的结构。
22.根据权利要求1所述的方法，其特征在于，在该方法中，在其中表面元件(1)被提供一个耐磨层(2″)并且压向该层的步骤期间，每个形成一个表面结构段的两种或多种表面结构基材准确定位在表面元件(1)的装饰侧上，这些段关于结构是彼此独立的，并且该所述表面结构段打算与在装饰中的对应图案段重合，由此耐磨层(2″)接收与在装饰层中的不同图案段相对应的表面结构(2)。
23.根据权利要求21所述的方法，其特征在于，一种或多种基材形成一个或多个轧辊的结构表面，从而表面元件(1)在结构轧辊与匹配的相对支撑辊之间、在轧辊与匹配的相对支撑之间的连续或不连续压力下通过。
24.根据权利要求23所述的方法，其特征在于，包含两种或多种基材的轧辊装有适应装饰方向重复变化频率的圆周。
25.根据权利要求22所述的方法，其特征在于，一种或多种基材在一个压制带上形成结构表面，由此表面元件(1)在压制带与一个压制带相对支撑之间的连续或不连续压力下，在压制带与压制带相对支撑之间通过。
26.根据权利要求22所述的方法，其特征在于，一种或多种基材形成一个或多个静止模具的结构表面，该结构表面瞬时地压向表面元件(1)的装饰侧。
27.根据权利要求21所述的方法，其特征在于，从由模拟板、条、块、节、裂纹、裂痕之间的边界线以及在装饰(2’)中模拟的纹理构成的组中选择的特征装饰段，作为数字数据存储，当所述特征装饰段提供有适当的表面结构时，该所述数据用来指导自动雕刻或压制工具，并且该所述雕刻或压制工具通过在表面元件(1)上的预定固定点同步。
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106013677A (zh) * 2015-03-31 2016-10-12 日吉华株式会社 建筑板及其制造方法
CN106013677B (zh) * 2015-03-31 2020-02-28 日吉华株式会社 建筑板及其制造方法

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