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

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 ka 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 kb 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 kc is determined,
• and
• the correction factor K is calculated from formula (I):
• K=ka+kb+kc+kd (I),
• where
• kd can be present or absent, and if present is the partial correction factor resulting from one or more further process steps;
• and
• ka, kb, kc, and kd 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.