US 12,311,686 B2
Methods for manufacturing panels having a decorative surface
Benjamin Clement, Waregem (BE); Laurent Meersseman, Kortrijk (BE); Patrick Van Den Bergen, Hove (BE); and Rudi Vanhooydonck, Zwijndrecht (BE)
Assigned to Unilin, BV, Wielsbeke (BE); and AGFA, NV, Mortsel (BE)
Filed by UNILIN BV, Wielsbeke (BE); and AGFA, NV, Mortsel (BE)
Filed on Feb. 20, 2023, as Appl. No. 18/171,484.
Application 18/171,484 is a continuation of application No. 17/218,671, filed on Mar. 31, 2021, granted, now 11,613,133.
Application 17/218,671 is a continuation of application No. 16/135,454, filed on Sep. 19, 2018, granted, now 10,994,555, issued on May 4, 2021.
Application 16/135,454 is a continuation of application No. 15/115,020, granted, now 10,124,603, issued on Nov. 13, 2018, previously published as PCT/IB2015/050823, filed on Feb. 3, 2015.
Claims priority of application No. 14154197 (EP), filed on Feb. 6, 2014.
Prior Publication US 2023/0191800 A1, Jun. 22, 2023
Int. Cl. B41J 3/407 (2006.01); B05D 7/06 (2006.01); B32B 21/02 (2006.01); B32B 21/08 (2006.01); B32B 37/00 (2006.01); B41J 2/14 (2006.01); B41M 5/52 (2006.01); B44C 5/04 (2006.01); E04F 13/08 (2006.01); E04F 13/10 (2006.01); E04F 15/02 (2006.01); E04F 15/04 (2006.01)
CPC B41J 3/407 (2013.01) [B05D 7/06 (2013.01); B32B 21/02 (2013.01); B32B 21/08 (2013.01); B32B 37/0038 (2013.01); B41J 2/14 (2013.01); B41M 5/52 (2013.01); B44C 5/0469 (2013.01); E04F 13/0871 (2013.01); E04F 13/0894 (2013.01); E04F 13/10 (2013.01); E04F 15/02038 (2013.01); E04F 15/04 (2013.01); B32B 2255/12 (2013.01); B32B 2255/26 (2013.01); B32B 2471/00 (2013.01); E04F 2201/0153 (2013.01); E04F 2201/023 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A method for manufacturing a paper layer having a printed pattern for use in panels that at least include a substrate and a top layer, wherein the top layer includes the paper layer, the method comprising:
providing the paper layer with an inkjet receiver coating by transporting the paper layer relative to a coater in a coating direction;
wherein the inkjet receiver coating includes a polyvinyl alcohol binder and silica pigments;
providing the coated paper layer with at least a portion of the printed pattern using a digital inkjet printer that includes a housing containing print heads;
wherein providing the portion of the printed pattern involves using water based pigment containing inks;
wherein the printed pattern comprises a wood motif having wood nerves extending generally in a nerve direction substantially corresponding to the coating direction;
wherein providing the printed pattern involves a relative motion between the digital inkjet printer and the paper layer during a printing operation in a printing direction substantially corresponding or substantially opposite to the coating direction;
wherein the paper layer is maintained flat inside the housing, or the minimum radius over which the paper layer is bent inside the housing is larger than 25 centimeters;
wherein the paper layer is fed from a roll, printed upon, and rolled back up again;
wherein the inkjet receiver coating is obtained from a liquid substance that is deposited on the paper layer; and
wherein the liquid substance has a viscosity of 10 to 75 seconds Din cup 4 at 20° C.