Process for the manufacturing of surface elements with a structured upper surface
AssigneePergo (Europe) AB
InventorsKrister Hansson, Johan Lundgren, Hakan Wernersson
Life of this patent
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Abstract
A process for the manufacturing of a decorative surface element, which element comprises a base layer and a decorative upper surface. A wetting repellent lacquer is printed in a predetermined pattern on the decorative upper surface. The wetting repellent lacquer covers only parts of the decorative upper surface. A wear layer of a UV or electron beam curing lacquer is then applied on top of the decorative upper surface which UV or electron beam curing lacquer is repelled from the parts of the surface being covered by the wetting repellent lacquer whereby a surface structure is achieved.
Claims37
A process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being at least one of a tongue-and a groove, the upper surface comprises a base layer and a decorative upper surface, the process comprising,
- i) providing the decorative upper surface with a decor layer, the decor layer comprising a pattern;
- ii) printing a wetting repellant lacquer in a predetermined pattern on the decorative upper surface, at least partially matching the pattern on the decor layer, the wetting repellant covering only part of the decorative upper surface, thereafter
- iii) applying a wear layer of a UV or electron beam curing lacquer on top of the decorative upper surface, which UV or electron beam curing lacquer is repelled from the part of the surface being covered by the wetting repellant lacquer whereby a surface feature is achieved;
- iv) sprinkling abrasion resistant particles, the particles being at least one selected from the group consisting of α-aluminum oxide, silicone carbide, silicon oxide and diamond, on the surface element;
- v) curing the wear layer;
- and
- vi) removing a portion of the particles by applying a high pressure air stream, thereby providing the building panel.
A process for process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising:
- applying a primer to a panel to form a primed panel;
- providing a decor layer on the primer, the decor layer comprising a pattern;
- printing wetting repellant lacquer on parts of the primed panel, matching the decor layer;
- placing a layer of UV or electron curing lacquer on the wetting repellent lacquer, whereby the UV or electron beam curing lacquer is repelled from the parts of the primed panel where the wetting repellant lacquer has been printed;
- sprinkling abrasion resistant particles on the surface element, the particles being at least one selected from the group consisting of α-aluminum oxide, silicone carbide, silicon oxide and diamond;
- curing the UV or electron curing lacquer;
- and
- removing a portion of the hard particles by applying a high pressure air stream.
A process for process for the manufacturing of a building panel, the building panel comprising a core, a decorative upper surface, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising process for the manufacturing of a decorative surface element, which element comprises a base layer and a decorative upper surface, the process comprising,
- i) selecting a digitized design at a first location;
- ii) transmitting the digitized design to a second location, remote from the first location;
- iii) providing the decorative upper surface with a decor layer, the decor layer comprising a pattern, the pattern being derived from the digitized design;
- iv) printing a wetting repellant lacquer in a predetermined pattern on the decorative surface, at least partially matching the pattern on the decor layer, the wetting repellant covering only part of the decorative surface, and thereafter
- v) applying a wear layer of a UV or electron beam curing lacquer on top of the upper surface, which UV or electron beam curing lacquer is repelled from the part of the surface being covered by the wetting repellant lacquer whereby a surface feature is achieved.
A process for the manufacturing of decorative surface, the surface being formed from a plurality of building panels, the building panels together forming a decorative surface, each building panel comprising an upper surface having a surface area, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising,
- i) selecting a design at a first location, wherein the design has a size larger than the surface area of each surface element;
- ii) dividing the design into a plurality of segments, each segment having a surface area corresponding to the surface area of one of the upper surfaces;
- iii) providing the upper surfaces with decor layers, the decor layers each comprising one segment of the design, such that when the building panels surface are installed, the design is reproduced across the plurality of building panels.
A process for the manufacturing of a decorative surface, the decorative surface being formed from a plurality of building panels, each building panel comprising an upper surface having a surface area, a lower surface, and edges joining the upper and lower surfaces, the edges being provided with at least one of a tongue and a groove, the process comprising,
- i) selecting a digitized design at a first location;
- ii) transmitting the digitized design via the Internet to a second location;
- and
- iii) providing the upper surfaces with a decor layer, the decor layer comprising a pattern, the pattern being derived from the digitized design.
Dependencies are inferred from the claim text.