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CN-121973439-A - Method for manufacturing a decorative panel and panel obtainable thereby

CN121973439ACN 121973439 ACN121973439 ACN 121973439ACN-121973439-A

Abstract

Method for manufacturing a decorative panel, wherein the panel comprises a panel base material (1) and a top decorative layer (9), wherein the method comprises the step of applying said top decorative layer (9) to said panel base material (1) at least by means of an additive manufacturing technique (10), more particularly by means of material spraying. The invention also relates to a panel (8) obtained or obtainable by such a method.

Inventors

  • Laurent Mellman
  • CLEMENT BENJAMIN

Assignees

  • 尤尼林有限公司

Dates

Publication Date
20260505
Application Date
20190314
Priority Date
20180314

Claims (15)

  1. 1. Method for manufacturing a decorative panel, wherein the method comprises at least the steps of: a step of providing a panel base material (1); a step of depositing a relief forming material from a suspension onto said panel substrate material (1), Characterized in that the suspension comprises particles and at least one binder.
  2. 2. The method of claim 1, wherein the particles comprise at least wood fibers.
  3. 3. The method according to claim 1 or 2, characterized in that the particles comprise at least wood chips.
  4. 4. The method according to any of the preceding claims, wherein the particles have an average particle size of equal to or less than 1 millimeter.
  5. 5. A method according to any one of the preceding claims, wherein the particles and the binder are present in the suspension in a particle/binder ratio of 40/60 to 95/5.
  6. 6. A method according to any one of the preceding claims, wherein the relief forming material is deposited with a first deposition device, and wherein the method comprises a step (S3) of depositing a trim forming material (3) on the panel base material (1) with a second deposition device, wherein at least the step of depositing the relief forming material (2) and the step of depositing the trim forming material (3) are performed in a single movement of the panel base material (1) relative to the first deposition device and the second deposition device.
  7. 7. A method according to any one of the preceding claims, wherein the relief forming material is deposited with a first deposition device, and wherein the method comprises a step (S3) of depositing a trim forming material (3) on the panel base material (1) with a second deposition device, wherein the first deposition device and the second deposition device each comprise a nozzle for spraying the respective material to the panel base material (1), and wherein the nozzle of the first deposition device is at a greater distance from the surface (4) of the panel base material (1) than the nozzle of the second deposition device.
  8. 8. A method according to any one of the preceding claims, wherein the relief forming material is deposited with a first deposition device and wherein the method comprises a step (S3) of depositing a decoration forming material (3) onto the panel substrate material (1) with a second deposition device, wherein the first deposition device deposits a relief forming material (2) having a particle size of more than 20 micrometers and/or having a droplet volume of more than 100 picoliters and the second deposition device deposits a decoration forming material (3) having a droplet volume of less than 50 picoliters.
  9. 9. A method according to any one of the preceding claims, wherein the relief forming material is deposited with a first deposition device and wherein the method comprises a step (S3) of depositing a decoration forming material (3) on the panel base material (1) with a second deposition device, wherein the first deposition device deposits the relief forming material (2) with a resolution lower than 100 dpi and the second deposition device deposits the decoration forming material (3) with a resolution higher than 200 dpi.
  10. 10. The method according to any one of the preceding claims, wherein the decorative panel (8) comprises a panel base material (1) and a top decorative layer (9), wherein the method comprises the step of applying the top decorative layer (9) to the panel base material (1) at least by an additive manufacturing technique (10), more particularly by material spraying.
  11. 11. The method according to claim 10, characterized in that the additive manufacturing technique (10) is applied to form a structured surface (11) on the panel base material (1).
  12. 12. The method according to any of the preceding claims, wherein the panel base material (1) is provided in a final shape or about in a final shape.
  13. 13. The method according to any of the preceding claims, wherein the panel base material (1) comprises a homogeneously colored top surface (4).
  14. 14. The method according to any of the preceding claims, wherein the panel base material comprises a flat top surface (4) or a structured top surface (4).
  15. 15. A method according to any of the preceding claims, characterized in that a relief forming material (2) is applied, which relief forming material comprises a polymer filled with at least 30wt% of a filling material.

Description

Method for manufacturing a decorative panel and panel obtainable thereby The present application is a divisional application of chinese patent application application No. 201980018921.1, having application date 2019, 3, 14, for a method for manufacturing a decorative panel and a panel obtainable thereby. Technical Field The present invention relates to a method for manufacturing a decorative panel, and to a panel obtained or obtainable with such a method. More particularly, the present invention relates to a method for manufacturing a trim panel of the type having a laminate structure (i.e. having at least a base material and a top trim layer disposed thereon). Background Such panels, in particular panels with a top decorative layer based on a synthetic material (for example based on a thermally hardening material, such as melamine or another thermally hardening amino resin), are known, for example, from patent documents WO 03/095202, EP 1 290 290, DE 33 34 921 A1, WO 2008/148771 and WO 2009/080813. From the above patent documents, various techniques for manufacturing such a laminate are known. Document EP 1 290 290 describes a widely spread method based on the conventional DPL (direct pressure lamination) technique for manufacturing laminated panels comprising at least a base material and a top decorative layer. This technique comprises at least the following steps: -a step of printing a decor paper; A step of forming a stack to be pressed from a base material, the above-mentioned decor paper and one or more layers of synthetic material for forming a transparent layer over the decor paper, and -A step of hot-pressing the stack. The particularity of DPL technology is that the top layer or laminate layer is formed by consolidating at least the decor paper and one or more layers of synthetic material. The consolidation includes at least hardening or cross-linking of the thermally hardened synthetic material. At the same time, i.e. by the same pressing process, this laminate layer is attached to the base material. During this pressing process, by structuring the pressing element, a relief can be formed in the surface of the laminate. Mass production of decorative panels according to the prior art techniques requires high investments in machinery, machining and inventory. In addition, these production techniques consume large amounts of energy, often resulting in waste raw materials and other waste materials and waste. Disclosure of Invention The object of the present invention is an alternative method for manufacturing a decorative panel with a laminated structure, which method provides advantages over the prior art according to its individual aspects and possible preferred embodiments. According to a first independent aspect thereof, the invention relates to a method for manufacturing a decorative panel, wherein the panel comprises a panel base material and a top decorative layer, wherein the method comprises at least the steps of: -a step of providing a panel base material; -a step of applying the top decorative layer to the panel base material at least by one or more additive manufacturing techniques, more particularly at least by material spraying (material jetting, material spray forming). Preferably, the additive manufacturing technique is applied at least to create a structured surface on the panel substrate material. Thus, preferably, additive manufacturing techniques are applied to deposit the relief forming material in a controlled manner, wherein the amount of relief forming material deposited is varied according to the predetermined relief pattern to be obtained. The resulting structured layer may be located below the printed decorative pattern, in which case an opaque material may be used for the relief forming material, and/or the structured layer may be located on top of the printed decorative pattern, in which case a translucent or transparent material may be used for the relief forming material. The structural layer may also be composed of several different colored relief forming materials, such that this structural layer also forms a decoration. Additive manufacturing is currently mainly used for prototyping, tooling and producing lightweight and/or complex components for example for aerospace or medical applications. As is generally known in the art of production engineering, additive manufacturing techniques preferably build a structural object or structural part of an object piece by piece, row by row, layer by layer, etc., based on digital information about the component or object to be obtained. The present application aims to more smoothly mass-produce decorative panels and provides a solution to this by using additive manufacturing to build a top decorative layer through its several independent aspects. Preferably, a technique of material jetting is applied, wherein droplets of material are selectively deposited on the panel substrate material. The material to be sprayed may be a polym