Methods and systems for decorating bevel and other surfaces of laminated floorings
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E04C-002/30
B41J-003/407
B41M-005/00
E04F-015/02
B41J-002/005
B41M-003/00
출원번호
US-0733293
(2013-01-03)
등록번호
US-9315994
(2016-04-19)
발명자
/ 주소
Chen, Hao A.
출원인 / 주소
Mannington Mills, Inc.
대리인 / 주소
Kilyk & Bowersox, P.L.L.C.
인용정보
피인용 횟수 :
1인용 특허 :
19
초록▼
Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) print
Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) printer that allows a color and pattern to be placed on the bevel surface that matches the print design (décor pattern or face design) of the laminated flooring. Other devices are provided such as a device that takes a picture of or scans an image of the print design, and modifies the taken picture or the scanned image so that the edge pattern thereof matches with an edge pattern of the print design.
대표청구항▼
1. A method of making a laminated flooring panel having at least one bevel surface, comprising non-transfer printing an ink onto the bevel surface to form a decorative pattern. 2. The method of claim 1, wherein the non-transfer printing is digital printing. 3. The method of claim 2, wherein the digi
1. A method of making a laminated flooring panel having at least one bevel surface, comprising non-transfer printing an ink onto the bevel surface to form a decorative pattern. 2. The method of claim 1, wherein the non-transfer printing is digital printing. 3. The method of claim 2, wherein the digital printing comprises ink jet printing. 4. The method of claim 1, wherein said non-transfer printing comprises printing with a printing system comprising at least four printheads aligned in a straight line and mounted at an angle of from 30 to 60 degrees with said printheads facing upward to said bevel surface, which is facing upside down. 5. The method of claim 4, wherein said printheads are mounted on a single master plate controlled by a servo motor, wherein said printheads are capable of being moved together simultaneously and said printheads are capable of rotating downward to face downward to purge ink. 6. The method of claim 5, wherein ink reservoirs for each printhead is located on said single master plate. 7. The method of claim 4, wherein said printheads have an ink throw distance of from 0.1 to 10 mm. 8. The method of claim 4, wherein said printheads have an ink throw distance of from 1-3 mm. 9. The method of claim 4, wherein said ink printing from said printheads has a meniscus pressure of −5.2 mbar to −0.1 mbar and has a meniscus tolerance of +/−2.0 mbar to +/−0.5 mbar. 10. The method of claim 1, wherein said bevel edge is surface treated prior to said non-transfer printing. 11. The method of claim 10, wherein said surface treating comprises applying at least one coating on said bevel surface prior to said non-transfer printing said ink, wherein said non-transfer printing is on said at least one coating. 12. The laminated flooring panel of claim 1, further comprising at least one coating located between said bevel surface and said non-transfer decorative pattern. 13. The method of claim 1, wherein said ink is a radiation curable ink, and said method further comprises curing said ink. 14. The method of claim 1, wherein said laminated flooring plank has at least one tongue or groove, and said method further comprises non-transfer printing said ink onto a surface of said tongue or said groove or both. 15. The method of claim 14, wherein said non-transfer printing of said tongue or said groove occurs at surfaces of said tongue or said groove that face upward. 16. The method of claim 1, wherein said non-transfer printing occurs at a print speed of at least 100 feet per minute, wherein said printing is upward and at an angle. 17. The method of claim 1, wherein said laminated flooring panel has a pre-printed décor pattern or face design on a top surface of said laminated flooring panel except on said bevel surface and the decorative pattern matches and lines up with the said pre-printed design of the laminated flooring. 18. The method of claim 1, wherein the decorative pattern simulates parquet, ceramic, stone, brick, marble, a wood grain pattern, a natural surface, or any combination thereof. 19. The method of claim 18, wherein the decorative pattern is a wood grain pattern. 20. The method of claim 1, wherein the bevel surface comprises high density fiberboard or medium density fiberboard. 21. The method of claim 1, further comprising the following steps: a) pressing or laminating multiple layers of material together,b) rip cutting a large size board into panels,c) cross cutting the panels into smaller panels,d) acclimating the panels by storing them in a controlled environment,e) profiling the panels to form at least one tongue and/or at least one groove, andf) beveling at least one side edge of the panels. 22. The method of claim 21, wherein the printing is performed on-line or in the same line of manufacture of at least one of steps a) to f). 23. The method of claim 1, wherein said ink is an ultraviolet light-curable ink. 24. The method of claim 1, wherein said ink is an electron beam-curable ink. 25. The method of claim 1, wherein the decorative pattern that is printed on the bevel surface has an image resolution of at least 300 dpi. 26. The method of claim 1, wherein the printing comprises at least four color process images. 27. The method of claim 1, wherein said laminated flooring panel has a print design on a top surface except on said bevel surface, and said method further comprising obtaining a digital picture of or scanned image of said print design, and modifying the digital picture or scanned image to have dimensions of said bevel surface. 28. A method of making a laminated flooring panel having at least one recessed surface, comprising non-transfer printing an ink onto the recessed surface to form a decorative pattern. 29. The method of claim 28, wherein said recessed surface simulates mortar, grout, or a border. 30. The method of claim 29, wherein said recessed surface is located away from an edge of said laminated flooring panel. 31. The method of claim 28, wherein the non-transfer printing is digital printing. 32. The method of claim 31, wherein the digital printing comprises ink jet printing. 33. The method of claim 28, wherein said non-transfer printing comprises printing with a printing system comprising at least four printheads aligned in a straight line and mounted with said printheads facing upward to said recessed surface, which is facing upside down. 34. The method of claim 33, wherein said printheads are mounted on a single master plate controlled by a servo motor, wherein said printheads are capable of being moved together simultaneously and said printheads are capable of rotating downward to face downward to purge ink. 35. The method of claim 34, wherein ink reservoirs for each printhead is located on said single master plate. 36. The method of claim 33, wherein said printheads have an ink throw distance of from 0.1 to 10 mm. 37. The method of claim 33, wherein said printheads have an ink throw distance of from 1-3 mm. 38. The method of claim 28, wherein said ink is a radiation curable ink, and said method further comprises curing said ink. 39. The method of claim 38, wherein said ink printing from said printheads has a meniscus pressure of −5.2 mbar to −0.1 mbar and has a meniscus tolerance of +/−2.0 mbar to +/−0.5 mbar. 40. The method of claim 28, wherein said laminated flooring panel has a pre-printed décor pattern or face design on a top surface of said laminated flooring panel except on said recessed surface and the decorative pattern matches and lines up with the said pre-printed design of the laminated flooring. 41. The method of claim 28, wherein the decorative pattern simulates parquet, ceramic, stone, brick, marble, a natural surface, or any combination thereof. 42. The method of claim 28, wherein the decorative pattern is a wood grain pattern. 43. The method of claim 28, wherein the recessed surface comprises high density fiberboard or medium density fiberboard. 44. The method of claim 28, wherein said ink is an ultraviolet light-curable ink. 45. The method of claim 28, wherein said ink is an electron beam-curable ink. 46. The method of claim 28, wherein the decorative pattern that is printed on the recessed surface has an image resolution of at least 300 dpi. 47. The method of claim 28, wherein the printing comprises at least four color process images. 48. The method of claim 28, wherein said laminated flooring panel has a print design on a top surface except on said recessed surface, and said method further comprising obtaining a digital picture of or a scanned image of said print design, and modifying the digital picture or scanned image to have dimensions of said recessed surface. 49. The method of claim 28, further comprising surface treating said recessed surface prior to said non-transfer printing. 50. The method of claim 49, wherein said surface treating comprises applying at least one coating on said recessed surface prior to said non-transfer printing said ink, wherein said non-transfer printing is on said at least one coating.
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