METHOD FOR PRODUCING A SAME PATTERN USING A SIMPLE PRINT AND DEVICE THEREOF

Abstract

A method for producing a pattern, in particular a wood pattern, on the face of a woodbased-material board. The pattern is preset with the aid of a digital data set and applied to the woodbased-material board via an intaglio printing process. The pattern is covered with at least one synthetic resin layer and pressed with the woodbased-material board. The digital data set is used to produce a sample print by use of an inkjet printing process, which print is used to compare with the pattern print on the woodbased-material board in terms of optical appearance. The materials and/or printing conditions used in the pattern printing and the sample printing are coordinated with one another.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

FIGS. 1 a-d represent a process flow and device according to the invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

Referring to FIG. 1a, a pattern, e.g., in the form of a wood grain, is provided in the form of original data 1 obtained by photographing an original pattern by a digital camera. A data set 4 that can be used in an inkjet printer 3 is generated from the original data 1 with the aid of an electronic device 2. In addition to the original data 1, the data set 4 contains additional control data or control parameters 4a to control inkjet nozzles. A woodbased-material board 5 is now printed with the aid of the inkjet printer.

A printing ink suitable for series production is used as a printing medium. Within the scope of the invention, the ink withstands the high pressure and the temperature stresses in the pressing operation of the woodbased-material board in a short-cycle press as is known in the art. After printing, the woodbased-material board 5 is coated with a first synthetic resin-based layer that preferably contains melamine resin or resinous resin. According to the invention, corundum particles are embedded in this first layer to establish the desired abrasion-resistance.

Another likewise synthetic resin-based finish coating is applied to the first layer. The synthetic resin layers are pressed with the printed woodbased-material board 5 in a short-cycle press in a manner known to those of ordinary skill in the art. The product thus obtained, having small dimensions of preferably board lengths between 1 to 2 m and board widths of the same kind, can now be studied with regard to its optical appearance.

Referring to FIG. 1b, if the pattern applied with the aid of the inkjet printer 3 meets the requirements of the purchaser or customer, a further data set 6 can be generated from the original data 1 according to the data set 4 as the basis for an indirect intaglio printing process. This provides advantages in particular if woodbased-material boards provided with the desired pattern are to be produced in large production runs

As further shown in FIG. 1b, control parameters 6a for controlling a laser 8 (see, FIG. 1c) are added to the original data 1 with an electronic, preferably computer-operated read/write device shown by reference number 7 in a general manner. As further shown in FIG. 1c, a print roller 9 is engraved according to the original data 1 with the aid of the control parameters 6a. According to the invention the further data set 6 as well as the data set 4 are analogously generated from the original data 1 by addition of the respective corresponding control parameters.

After the completion of the print roller 9 by engraving, e.g., laser engraving, the printing of large sized woodbased-material boards 10 is carried out as shown in FIG. 1d. This printing can be carried out in a conventional intaglio printing process using a printing ink used in the inkjet printing process and a corresponding printing color in terms of the optical image in a series production installation. The pattern corresponding to the original data 1 is applied via a form roller 11. A conformity in terms of optical appearance is thus ensured according to the invention between the woodbased-material board 5 produced for inspecting a small production run (sample run) of approximately one to ten and with small dimensions and the woodbased-material boards 10 provided with the same pattern in a series production process.

As should be understood, the original digital data set controls the printing on the first base material and the second base material so that a number of image points per unit area on the first base material essentially corresponds to a number of image points per unit area on the second base material. Also, a size of the image points and nozzle spacings of the printing on the first base material are coordinated with a size of screen dots and raster sizes in a printing process of the second based material, and identical printing liquids are used for the printing of the pattern on the first base material and the second based material.

It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

Claims

1. A method for producing a same pattern comprising a plurality of image points on respectively one side of two different base materials from an original digital data set comprising: printing a pattern on one side of a first base material as a sample print;covering the pattern with a synthetic resin layer;pressing the first base material with the pattern and the synthetic resin layer;printing the pattern on one side of a second base material;covering the pattern on the second base material with a synthetic resin layer;pressing the second base material with the pattern and the synthetic resin layer, whereinthe original digital data set controls the printing on the first base material and the second base material so that a number of image points per unit area on the first base material essentially corresponds to a number of image points per unit area on the second base material and a size of the image points and nozzle spacings of the printing on the first base material are coordinated with a size of screen dots and raster sizes in a printing process of the second based material and identical printing liquids are used for the printing of the pattern on the first base material and the second based material.

2. The method according to claim 1, wherein identical solvents, pigments and binders are used for printing liquids.

3. The method according to claim 1 wherein Ma woodbased-material board, a plastic board, a stone slab, a linoleum board or a decorative paper is used as a base material.

4. The method according to claim 3, wherein a surface structure synchronous to the pattern is embossed during the pressing of the first and second base materials with the pattern and the synthetic resin layer.

5. The method according to claim 3, wherein the first base material and the second base material are provided with a chamfer on at least two opposite edges.

6. The method according to claim 1, wherein the raster of a print roller for intaglio printing is produced by a laser, an etching process or an erosion process.

7. The method according to claim 6, wherein the printing of the pattern on the second base material is carried out in an indirect intaglio printing process.

8. The method according to claim 1, wherein the printing a pattern on the first base material as a sample print is performed with an inkjet printer.

9. The method according to claim 1, wherein the printing a pattern on the second base material is performed by a print roller with a raster in an intaglio printing process.

10. The method of claim 1, wherein: the printing a pattern on the first base material as a sample print is performed with an inkjet printer;the printing a pattern on the second base material is performed by a print roller; andthe original digital data set controls the inkjet printer and produces the print roller so that the number of image points per unit area on the first base material essentially corresponds to the number of image points per unit area on the second base material and the size of the image points and the nozzle spacings of the inkjet printer are coordinated with the size of the screen dots and the raster sizes in intaglio printing process.

11. A method of printing, comprising: providing a pattern in a form of original data;generating a data set used in a printing process generated from the original data;printing a first material board using the data set;coating the first material board with at least a first synthetic resin-based layer;pressing the at least first synthetic resin layer with the printed first material board in a short-cycle press;generating a further data set from the original data as the basis for an indirect printing process;adding control parameters for controlling a laser to the original data; andengraving a print roller according to the original data with aid of the control parameters, wherein the further data set and the data set are analogously generated from the original data by addition of respective corresponding control parameters;printing the pattern on one side of a second material board with the print roller using the further data set;covering the pattern on the second material board with a synthetic resin layer; andpressing the second material board with the pattern and the synthetic resin layer.

12. The method according to claim 11, wherein the providing a pattern is obtained by photographing an original pattern by a digital camera.

13. The method according to claim 11, wherein the at least first synthetic resin layer contains melamine resin or resinous resin.

14. The method according to claim 13, wherein the at least first synthetic resin layer contains embedded corundum particles,

15. The method according to claim 11, wherein the data set contains additional control data or control parameters to control inkjet nozzles.

16. The method according to claim 11, wherein the original data controls the printing on the first material board and the second material board so that a number of image points per unit area on the first material board essentially corresponds to a number of image points per unit area on the second material board and a size of the image points and nozzle spacings of the printing on the first material board are coordinated with a size of screen dots and raster sizes in a printing process of the second material board and identical printing liquids are used for the printing of the pattern on the first material board and the second material board.

17. A device for printing, coating and pressing two different base materials with a same pattern, which is covered with a synthetic resin and subsequently pressed therewith, wherein the device comprises a first printing line and a second printing line, a pattern is applied to a first base material as a sample print using an inkjet printer in the first printing line and a same pattern is applied to a second base material using an intaglio printing device in the second printing line, and a test unit provided on an exit side with an optical scan element and a comparison unit compares the printing results of the first and second printing line with respect to optical appearance.

18. The device according to claim 17, wherein the optical scan element has a control unit in which results obtained in a scanning process are compared to a preset data set, and if there is conformity or if the deviations are acceptable a switching pulse is transmitted to control the second printing line.

19. The device according to claim 17, wherein the pattern is applied with an indirect intaglio printing device in the second printing line.