CN117337240A

CN117337240A - Method for producing a decorative panel and decorative panel

Info

Publication number: CN117337240A
Application number: CN202280034635.6A
Authority: CN
Inventors: 洛朗·梅尔斯曼; 克里斯托夫·奈亚尔特; 简·德·里克; 本尼·沙赫特
Original assignee: Flooring Industries Ltd SARL
Current assignee: Unilin BV
Priority date: 2021-05-12
Filing date: 2022-05-09
Publication date: 2024-01-02

Abstract

Method for manufacturing a decorative panel, wherein the panel (1) comprises a substrate (2) and a decorative top layer (3), wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate (2) and/or the decorative top layer (3) are obtained from a larger material by a splitting operation (S1), wherein the panel (1) comprises a low edge region (6) at least one upper edge of a pair of opposite side edges and preferably at two upper edges (5), wherein the low edge region (6) is obtained before or during the splitting operation (S1). The invention further relates to a decorative panel (1) obtainable by such a method.

Description

Method for producing a decorative panel and decorative panel

Technical Field

The present invention relates to a method for manufacturing a decorative panel, and a decorative panel obtainable by such a method. The invention is primarily directed to floor panels, but may also be implemented with wall panels, ceiling panels or furniture panels.

More particularly, the invention relates to floor panels of the type consisting at least of a substrate and a decorative top layer forming a decorative surface, wherein the top layer comprises a motif. A transparent or translucent synthetic material layer may be provided over the motif, which layer then forms part of the top layer.

In particular, the invention relates to floor panels of the type comprising coupling means or coupling parts at two or more opposite edges, with which two such floor panels can be coupled at the respective edges such that they are locked together in a horizontal direction perpendicular to the respective edges and in the plane of the floor panels, and in a vertical direction perpendicular to the plane of the floor panels. Such floor panels are applicable to constitute so-called floating floor coverings (floating floor covering), wherein the floor panels are interconnected at their edges, however, free to lay flat on the subfloor.

Background

From WO97/47834, EP1290291 and WO2006/066776 laminate floor panels are known for forming floating floor coverings. However, laminate floor panels show the disadvantage that they are often provided with a moisture-sensitive substrate, i.e. MDF or HDF (medium density fiberboard or high density fiberboard), and that the top layer provided on said substrate results in an irritating noise when the floor covering is used. It is known from EP1290291 to provide a laminate floor panel with a bevelled edge portion formed by removing a material portion from the edge of the floor panel, thereby exposing a portion of the core material. It is known from WO2006/06676 to form the inclined edge portion by compressing the core material such that the top layer extends uninterruptedly from the entire surface of the panel to the inclined edge portion and beyond the inclined edge portion.

From EP1938963 vinyl floor panels are known for forming such floating floor coverings. Such vinyl floor panels are typically 3 to 5 millimeters thick and have a high material density. WO2011/141,849 and WO2014/117,887 disclose decorative panels with a foamed core. WO2012/004701 discloses that the vinyl floor panel may also be provided with a beveled edge portion by machining away material portions and exposing layers underneath the pattern, or by deforming the surface of the panel such that the pattern also extends over the beveled edge portion.

Disclosure of Invention

The present invention relates to an alternative method of manufacturing a decorative panel, which decorative panel is intended in particular as a floor panel for forming a floating floor covering. There is also provided, in accordance with various preferred embodiments of the present invention, a solution to one or more of the problems of the prior art floor panels and methods of manufacturing the same.

To this end, the invention is a method for manufacturing a decorative panel, wherein the panel comprises a substrate and a decorative top layer, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate and/or decorative top layer is obtained from a larger material by a dividing operation, characterized in that the panel comprises a low edge area at least one upper edge and preferably at both upper edges of a pair of opposite side edges, wherein the low edge area is obtained before or during the dividing operation. Obtaining a low edge area while the trim panel material still forms part of a larger material allows for a smoother production process. For example, any bulging or undesired deformation of the larger material due to the formation of the low edge region may be concentrated in a portion of the larger material that will be removed in a subsequent step, e.g. during or after the singulation operation. Furthermore, the method of the invention allows positioning the splitting operation with respect to said upper edge having said low edge region, for example such that the opposite side edges have a low edge region of a predetermined size or shape. Further, in the case where such larger material comprises two or more decorative panels, the low edge regions at two or more upper edges of the two or more decorative panels may be formed in the same operation. In this case, the low edge regions can be made very similar with limited effort. According to the present invention, and throughout the specification, the term "cut edge" refers to an edge along which a slab of base material is physically cut from a larger material (e.g., a slab of base material) by a singulation operation. The term "upper edge" relates to an edge formed on the upper side of the panel, and the low edge region is formed adjacently along the edge.

Preferably, the dividing operation comprises performing a cutting operation to release at least the substrate from the larger material at least two opposite side edges.

Preferably, the cutting operation forms opposing cutting edges for releasing the at least two opposing side edges, wherein the opposing cutting edges are positioned at mutually different distances from the upper edge of the panel. The different distances allow for the formation of contoured edges that extend horizontally beyond the respective upper edges differently while minimizing material loss.

Preferably, the singulation operation comprises a cutting operation, more particularly a stamping operation, i.e. an operation in which a stationary (i.e. non-rotating) cutting blade or knife is pressed down onto, into and through the material to be cut.

The low edge region may be formed using one or more of a number of different methods, some of which are described below as important possibilities and are not intended to be exhaustive.

According to a first possibility, the low edge region is formed simultaneously with the splitting operation, i.e. during the splitting operation, or almost simultaneously with the splitting operation. In this way, a very precise positioning of the cutting edge with respect to the upper edge of the panel is obtained. In case the forming tool is engaged with the larger material at least during a part of said dividing operation, the respective low edge region is considered to be formed simultaneously with or during the dividing operation, and the low edge region is considered to be obtained during said dividing operation. In the case where the forming tool engages with the larger material while the larger material is within the singulation apparatus and/or aligned with the operational position of the cutting tool, and the cutting tool is disengaged prior to engagement with the larger material, the corresponding low edge regions are considered to be formed at least partially prior to, but nearly simultaneously with, the singulation operation. According to the present invention, and throughout the specification, the terms "simultaneous" and "during" in connection with the forming of the low edge region and the dividing operation should be interpreted as said forming of the low edge region and the dividing operation are preferably performed simultaneously and/or at least partly overlapping. The term "almost simultaneously" is indicated here to allow a slight time gap between the splitting operation and the formation of the low edge region, while nevertheless a very precise positioning of the cut edge with respect to the upper edge of the panel is still obtained. Such a minute time gap may constitute a gap of less than 1.0 seconds, preferably less than 0.9 seconds, less than 0.8 seconds, less than 0.7 seconds, less than 0.6 seconds or less than 0.5 seconds. Such a small time gap may also constitute a gap of less than 10%, preferably less than 9%, less than 8%, 7%, 6%, 5%, 4%, 3%, 2% or less than 1% of the duration of the forming of the low edge region and/or the dividing operation.

According to a practical implementation of, for example, the first possibility, the splitting operation comprises:

-providing the larger material in a dividing device;

-recessing the larger material at the location of the upper edge so as to at least partially form the low edge region;

-releasing the substrate and/or the decorative top layer from the larger material by a cutting operation using a cutting tool, for example by a knife being forced into and through the larger material.

Preferably, the recessing is performed by a mould or mould parts pressed down on the substrate and/or the decorative top layer. The mould or mould parts may be engaged with the substrate and/or the decorative layer at the beginning of the cutting operation and preferably still engaged at the end of the cutting operation. In case the mould or mould parts are joined with a larger material at least during a part of said cutting operation, the respective low edge regions are formed at least partly simultaneously with or during the dividing operation. In this way, the material to be cut can be kept stationary and a precise positioning of the cutting edge can be obtained. Preferably, the die or die portion is movable relative to the cutting tool. Preferably, the mould or mould parts are substantially stationary during the cutting operation, i.e. when the cutting tool is moved into and through the substrate and/or decorative layer.

According to a second possibility, the low edge region is preferably formed in correspondence with the cutting operation, prior to the cutting operation, which releases at least the substrate from the larger material at least two opposite edges. The conforming operation allows to precisely position the cutting operation with respect to the lower edge region or the final upper edge of the trim panel to be obtained.

According to said second possibility, the formation of the low edge region is preferably formed using a continuous forming or deforming operation. Preferably, the low edge region is formed by one or more structured rollers and/or by one or more moving bands of debossing the larger material. Such an operation may be arranged smoothly with continuous operations, for example in line with extrusion and lamination operations for forming larger materials. The rollers and/or belts may form a low edge region as larger material is fed through the respective apparatus.

According to the second possibility, the cutting operation is preferably performed by means of a plurality of preferably rotating cutting tools. The cutting tool may be a saw blade or a rotary knife. Preferably, the cutting tool is positioned to form opposing cutting edges at a predetermined distance from the upper edge of the trim panel.

The position of the cutting tool may be controllable and/or based on an upstream portion of the larger material. For example, the cutting tool may be controlled to obtain said predetermined distance between the cutting edge and the corresponding upper edge. The upstream portion of the larger material may be recorded by an optical or tactile sensor, for example by one or more cameras or gauges. The upstream portion preferably comprises a portion within or at a fixed distance from the available low edge region and/or upper edge to be obtained. The upstream portion may be detectable due to its convexity, in the case of a low edge area, for example because it extends under the spherical surface of a larger material, or due to its decoration or marking.

As already mentioned above, preferably according to said first or second possibility, the method further comprises the step of providing the larger material comprising said substrate and/or decorative top layer by a continuous operation, preferably comprising one or more extrusion operations, spreading operations, pressing operations and/or lamination operations.

Preferably, according to said second possibility, said low edge region and said cutting operation are performed in correspondence with the step of providing said larger material.

According to a particular embodiment of the first or second possibility, the low edge region is formed by recessing the material at the edge of the pre-processed portion of larger material. By pre-processing, a portion of the material can be removed at the location where the low edge region is to be formed. In this way, less material must be displaced to form the low edge region and more accurate results can be obtained with less power required for deformation. Preferably, the pre-processed portion enters at least the substrate from the top of the larger material. Preferably, the pre-machined portion comprises an undercut, i.e. a portion that is available vertically below the remaining top surface portion of the larger material.

According to the second possibility, the method may further comprise the step of providing a larger material comprising at least the substrate, wherein the substrate is provided with a lowered substrate area at the location of the low edge area before the decorative top layer is applied to the substrate. According to one variant, the method may further comprise the step of providing a larger material comprising at least the substrate, wherein a decorative top layer is applied to the substrate, wherein the decorative top layer or a part thereof comprises a structure before it is applied to the substrate. Preferably, the structure of the top layer or a corresponding part thereof comprises the low edge region. Preferably, at least in the case of said variants, said decorative top layer comprises a plurality of layers and comprises a motif. The layer under the pattern may include thinned portions or openings that substantially correspond to the structure of the low edge region. Such thinned portions or openings may limit the deformation and power required to obtain one or more low edge regions. Preferably, at least two, preferably all, of the plurality of layers are laminated to each other prior to application to the substrate.

According to a third possibility, the method further comprises the step of providing a larger material comprising the substrate and/or the decorative top layer by means of a continuous or discontinuous pressing operation, wherein a plurality of prefabricated layers are adhered to each other. Preferably, the low edge region is formed simultaneously with the pressing operation. Preferably, the pressing operation is a discontinuous pressing operation, for example by a single-layer press or a multi-layer press. Such presses may comprise at least one pressing element associated with each larger material to be pressed, in the case of single-layer presses at least one pressing element being intended to be in contact with the decorative top layer and potentially comprising a pressing element intended to be in contact with the bottom of the larger material to be pressed. Such a pressing element, in particular a pressing element in contact with the decorative top layer, may be structured, which may for example involve a structured press plate or a structured foil. The pressing operation may be a heated pressing operation, possibly followed by a cooling operation under pressure, preferably in the same or separate but similar press.

According to the method of the third possibility, preferably at least one of the prefabricated layers may comprise thinned and/or removed sections, preferably at least at the location where the low edge region is obtained or is to be obtained. Such thinned portions or removed segments can limit the deformation and power required to obtain one or more low edge regions. Preferably, said at least one of said preformed layers is a thermoplastic layer from which segments have been removed by a cutting operation, more particularly by a stamping operation. Preferably, said at least one of said prefabricated layers is a single piece layer.

Typically, the larger material is preferably provided with a reference portion prior to the singulation operation, irrespective of whether one of the above possibilities is used or not. Such a reference portion may help to locate larger materials relative to further operations. Preferably, the reference portion is used to align the larger material to the singulation operation or a portion thereof, more particularly to one or more cuts performed therein, or vice versa, i.e. wherein the reference portion is used to align one or more cutting tools performing the cuts to the larger material, or both. For example, the alignment may be such that the low edge region is parallel to one or more of the cuts performed in the singulation operation.

The reference portion may comprise an indentation or recess provided in the bottom of the larger material. According to one variant or in combination with the preceding variant, the reference portion may comprise an edge of the larger material. According to another variant, the reference portion comprises a visual or tactile marking available at the side of the larger material comprising the low edge region.

Preferably, the reference portion is disposed at a predetermined distance from an upper edge of the panel.

Preferably, the reference portion cooperates with a stop or guide tool in the singulation operation. Thus, the reference portion may be performed as a recess for engagement with a part of a stop or guiding tool, either in the singulation operation or in another operation.

Preferably, according to the invention, the decorative top layer continues uninterruptedly from the entire upper surface of the panel to the low edge region and beyond the low edge region.

Preferably, the low edge region is formed as a straight or curved chamfer. According to a variant, the low edge region may be formed in an L-shape, i.e. with a horizontal or substantially horizontal bottom adjoining the upper edge and an upwardly extending wall portion at the proximal side of the low edge region.

Preferably, the low edge regions are available at both edges of a pair of opposed upper edges, wherein the low edge regions at opposed upper edges extend to each other to the same depth measured perpendicular to the upper edges and/or extend the same horizontal distance measured perpendicular to the upper edges. In the case where the low edge regions are formed as straight or curved chamfer surfaces, a so-called V-shaped groove may be formed when two low edge regions of a similar panel are adjacent in a covering formed of such a decorative panel.

For example, in the case of an L-shaped low edge region, it may be obtained at one or both of a pair of opposed upper edges. By means of the L-shaped low edge area, a simulation of a grout line, rubber or asphalt joint can be achieved.

Preferably, at least two substrates and/or top layers for the respective panels are obtained or obtainable from said larger material. Preferably, the larger material has a net-like or plate-like shape of a limited length, which is practically endless, wherein four or more rectangular panels are obtainable at least in one direction, for example in the width direction of the net or plate, wherein the width of the panels is preferably oriented in the same direction as the width of the net or plate.

As is clear from the above, preferably the substrate is compressed or deformed at the location of the low edge region.

In general, the substrate and/or the decorative top layer of the decorative panel of the present invention preferably exhibits one or a combination of two or more of the following properties:

the substrate and/or the decorative layer comprises a layer of foam material, for example a closed-cell foam of thermoplastic material (for example PVC). The usability of the foam layer is convenient, for example, in case the low edge region is at least partly formed by compression or deformation. The walls of the cell walls may collapse to create the low edge region or a portion thereof;

-the substrate and/or the decorative layer comprises one or more voids at least at a position vertically below said low edge region. The voids may be formed by cells of the foam layer, and/or may be formed by removing material from another solid material layer, and/or may be formed as open or closed cavities within the material layer of the substrate;

the substrate and/or the decorative layer comprise a material having a shore a hardness of less than 80 and preferably greater than 20. The layer of material having a relatively low hardness may be more easily deformed in order to create at least a part of the lower edge portion. Preferably, said material is available in the panel at least at a location immediately below said decorative layer.

The substrate may comprise at least one of magnesium oxychloride or magnesium sulfate sheet comprising a sheet or layer.

Alternatively, or in combination with the above, the substrate may comprise at least one plate or layer comprising a thermoplastic material, preferably a filled synthetic composite comprising a thermoplastic material and a filler, preferably a mineral filler, such as sand, talc, chalk or other forms of CaCO3.

Preferably, the decorative top layer comprises a motif, preferably formed by a printed pattern or a wood veneer. The decorative top layer may comprise a carrier layer and a transparent wear layer applied on top of the printed pattern, which is provided on the carrier layer. The carrier layer may be a thermoplastic foil, preferably a PVC foil, a paper layer or a wood veneer. Preferably, the wear layer is a thermoplastic foil.

According to a particular embodiment, the decorative top layer comprises, from bottom to top, at least a backing layer, a print carrier layer and a transparent wear layer. Preferably, the backing layer forms a substantial part of the thickness T of the decorative top layer, or at least 45% thereof. The decorative top layer is preferably assembled from the backing layer, the print carrier layer and the wear layer by thermal lamination, i.e. preferably no separate glue layer is present between the layers. Preferably, the decorative top layer or at least the bottom layer thereof is also connected to the substrate by thermal lamination, i.e. without a separate glue layer. However, it is not excluded that the decorative top layer or at least the bottom layer thereof is glued to the substrate.

Where the decorative layer comprises a backing layer, the backing layer is preferably a thermoplastic layer, preferably made of soft PVC, i.e. PVC with more than 10phr plasticizer, and/or thermoplastic foam material, such as foamed PVC.

In general, in addition to the first possibility described above for forming the low edge region, the low edge region is preferably formed by one or more structured rollers and/or by embossing one or more strips of the larger material.

As mentioned above, preferably the method of the invention comprises the step of providing the larger material comprising said substrate and/or decorative top layer by a continuous operation, preferably comprising one or more extrusion operations, spreading operations, pressing operations and/or lamination operations. Preferably, the step of providing the larger material comprises at least one or more extrusion operations and lamination operations, or at least one or more dispensing operations and lamination operations. During the lamination operation, the multiple layers may be laminated immediately, subsequently, or in any other order.

Preferably, the larger material comprises printed patterns of adjacent rectangular and oblong panels or tiles. For example, a printed pattern applied to a carrier layer, such as a thermoplastic foil. Preferably, the low edge region is available at least between adjacent longitudinal edges of the panel or tile. The longitudinal edges of the panels or tiles may be directed in the direction of feed of the continuous operation. According to a variant, the longitudinal edges of the panels are transverse to the feed direction. In the latter case, the possible stretching of the printed pattern can be controlled in an enhanced manner, and the forming operation of the low edge region and the dividing operation can be performed more accurately. In case a printed thermoplastic foil is used, for example a printed PVC foil may be used. Such PVC foil may be of the soft or semi-rigid or rigid type. PVC foils of the rigid type, i.e. comprising 0 to 5phr of plasticizer, are preferred in order to minimize possible elongation of the PVC foil during processing (e.g. lamination).

Preferably, the larger material is a flat mesh substrate material, e.g. having a width W of 1 to 2.1 meters, preferably about 1.3 meters, and preferably having a thickness T2 of 2 to 7 millimeters, preferably 3 to 6 millimeters, more preferably 3 to 5 millimeters, even more preferably 3.5 to 4.5 millimeters, e.g. about 4 millimeters. Preferably, the flat web shaped substrate material is provided in a continuous length, for example by an extrusion operation.

The orientation of the longitudinal edges of the rectangular and oblong panels transverse to the feed direction in the lamination operation also forms an inventive aspect of the invention, irrespective of whether low edge regions are available or formed. This independent aspect may be defined as a method for manufacturing a decorative panel, wherein the panel comprises a substrate and a decorative top layer, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate and decorative top layer are obtained from a larger material by a dividing operation, characterized in that the method comprises a laminating operation for arranging at least a part of the decorative top layer on the substrate, wherein the laminating operation is a continuous operation, wherein the respective part of the decorative top layer is fed to the laminating operation in a feeding direction, and wherein the panel is rectangular and oblong with its longitudinal edges directed transversely to the feeding direction. Preferably, the method further comprises an embossing operation and/or a forming operation for forming the low edge region.

Performing a dividing operation to divide the larger material into panels in a direction transverse to the feeding direction of the larger material also forms an inventive aspect of the invention, irrespective of whether a low edge region is available or formed. This independent aspect may be defined as a method for manufacturing a decorative panel, wherein the panel comprises a substrate and a decorative top layer, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate and/or decorative top layer is obtained from a larger material by a dividing operation, and wherein the dividing operation is performed to divide the larger material into slabs comprising a single panel or more than one panel in a direction transverse to a feeding direction of the larger material.

Preferably, the slab including more than one panel is further divided into slabs including single panels by a secondary division operation.

According to some embodiments, the panel preferably comprises at least one and a plurality of low edge regions at both upper edges of a pair of opposite side edges, wherein the low edge regions are obtained prior to, during or substantially simultaneously with the splitting operation. More preferably, the low edge region is obtained during the splitting operation or is obtained almost simultaneously with the splitting operation. In this way, a very precise positioning of the cutting edge with respect to the upper edge of the panel is obtained.

Obtaining a low edge area while the trim panel material still forms part of a larger material allows for a smoother production process. For example, any bulging or undesired deformation of the larger material due to the formation of the low edge region may be concentrated in a portion of the larger material that will be removed in a subsequent step, e.g. during or after the singulation operation.

Furthermore, the method of the invention allows positioning the splitting operation with respect to said upper edge having said low edge region, for example such that the opposite side edges have a low edge region of a predetermined size or shape. Furthermore, in case such larger material or such blank comprises two or more trim panels, the low edge areas at two or more upper edges of said two or more trim panels may be formed in the same operation. In this case, the low edge regions can be made very similar with limited effort.

Preferably, the dividing operation comprises performing a cutting operation with a cutting tool, releasing at least the substrate from the larger material at least two opposite side edges.

Preferably, the cutting operation forms opposing cutting edges for releasing the at least two opposing side edges, wherein the opposing cutting edges are positioned at mutually different distances from the upper edge of the panel. The different distances allow for the formation of contoured edges that extend horizontally beyond the respective upper edges differently, while minimizing material loss.

In some embodiments, the singulation operation includes a fixed cutting operation, more particularly a stamping operation, i.e., an operation in which a fixed (i.e., non-rotating) cutting blade or knife is pressed down into, and through the material to be cut, and is oriented transversely with respect to the feed direction of the larger material. In some embodiments, the singulation operation comprises a non-stationary cutting operation, i.e. an operation in which a non-stationary (i.e. rotating) roller is operated, the roller comprising a knife-shaped protrusion that intermittently engages the material to be cut by rotation of the roller, and that is oriented transversely with respect to the feed direction of the larger material.

In some embodiments, the cutting blade or knife, or knife-shaped protrusion, may include a cutting edge that is substantially parallel to the plane of the larger material to be segmented. In some embodiments, the cutting blade or knife, or knife-shaped protrusion, may have a cutting edge that is not parallel to the plane of the larger material to be segmented. Preferably, the cutting blade or knife, or knife-shaped protrusion, may have a cutting edge that is slightly angled with respect to the plane of the larger material. In particular, the cutting edge may be at an angle of at least more than 0.10 ° with respect to the plane of the larger material. More particularly, the cutting edge may be at an angle of at least more than 0.25 ° relative to the plane of the larger material, at an angle of at least more than 0.50 °, 0.75 °, 1.00 °, 1.25 °, 1.50 °, 1.75 °, 2.00 °, 2.25 °, or at an angle of at least more than 2.50 ° relative to the plane of the larger material.

According to some embodiments, the secondary dividing operation comprises a cutting operation with a cutting tool, releasing at least the substrate from the slab comprising more than one panel at least two opposite side edges, wherein the opposite cutting edges are positioned at mutually different distances from the upper edge of the panel.

According to some embodiments, the secondary singulation operation comprises a fixed cutting operation, more particularly a stamping operation, i.e. an operation in which a fixed (i.e. non-rotating) cutting blade or knife is pressed down into, into and through a slab comprising more than one panel.

According to some embodiments, the secondary singulation operation comprises a non-stationary cutting operation, more particularly a sawing operation, i.e. an operation in which a rotating cutting blade or knife is moved into and through a slab comprising more than one panel.

According to a practical embodiment, for example, the dividing operation includes:

-providing the larger material in a dividing device;

-releasing the substrate and/or the decorative top layer from the larger material by a cutting operation with a cutting tool, for example by a cutting blade or knife being pressed down into the larger material, into the larger material and through the larger material, or by a roller comprising a knife-shaped protrusion, which protrusion is intermittently engaged with the larger material by rotation of the roller.

According to some embodiments, the low edge region is obtained by recessing the larger material by means of a mould or mould part at the location of the upper edge.

The mould or mould parts may be joined to the substrate and/or the decorative layer at the beginning of the singulation operation, preferably still joined at the end of the singulation operation. In case the mould or mould parts are joined with a larger material at least during a part of said dividing operation, the respective low edge regions are formed at least partly simultaneously with or during the dividing operation. In this way, the material to be cut can remain fixed and a precise positioning of the cutting edge can be obtained.

Preferably, the die or die sections are movable relative to the cutting tool. Preferably, the mould or mould parts are substantially stationary during the cutting operation, i.e. when the cutting tool is moved into and through the substrate and/or decorative layer.

In particular, where the cutting tool involves a cutting blade or knife, the die or die portions may be formed as a single entity with the cutting blade or knife. Alternatively, the die or die portions may be formed as separate entities from the cutting blade or knife, wherein the cutting blade or knife is movable relative to the die or die portions.

In particular, where the cutting tool relates to a roller comprising a knife-shaped protrusion, the mould or mould parts may be formed as auxiliary protrusions on the roller, comprised on at least one side, preferably on both sides, of the knife-shaped protrusion.

According to some embodiments, the low edge region is formed in line with the cutting operation, preferably before the cutting operation, at least the substrate is released from the larger material at least two opposite edges. The conforming operation allows to precisely position the cutting operation with respect to the lower edge region or the final upper edge of the trim panel to be obtained.

According to the embodiment, the formation of the low edge region is preferably formed using a continuous forming or deforming operation. Preferably, the low edge region is formed by one or more structured rollers and/or by one or more moving belts that indent the larger material. Such operation may be arranged in fluent correspondence with continuous operations (e.g., extrusion and lamination operations for forming larger materials). The rollers and/or belts may form a low edge region as larger material is fed through the respective apparatus.

In some embodiments, the decorative top layer continues uninterrupted from the entire upper surface of the panel to and over the low edge region. The lower edge regions at opposite upper edges may extend the same depth as measured perpendicular to the upper edge and/or extend the same horizontal distance as measured perpendicular to the upper edge. Preferably, the substrate may be compressed or deformed at the location of the low edge region.

According to another or another embodiment, the substrate and/or decorative top layer may exhibit one or a combination of two or more of the following properties:

the substrate and/or the decorative layer comprises a layer of foam material, for example a closed-cell foam of thermoplastic material (for example PVC);

-the substrate and/or the decorative layer comprises one or more voids at least at a position vertically below said low edge region;

the substrate and/or the decorative layer comprise a material having a shore a hardness of less than 80 and preferably greater than 20.

Preferably, the substrate may comprise at least one sheet or layer comprising a thermoplastic material, preferably a filled synthetic composite comprising a thermoplastic material and a filler, preferably a mineral filler, such as sand, talc, chalk or other forms of CaCO3, and the decorative top layer comprises a motif, preferably formed by a printed pattern or a wood veneer.

Drawings

In order to better illustrate the features according to the invention, several embodiments will be described below, as non-limiting examples of features, with reference to the accompanying drawings, in which:

fig. 1 schematically shows some steps in a method according to the invention;

fig. 2 shows a cross-section according to the line II-II shown in fig. 1 on a larger scale;

fig. 3 shows a cross-section according to the line III-III shown in fig. 1 on a larger scale;

fig. 4 shows the method at different points in time in the same view as fig. 3;

fig. 5 schematically shows some steps in another method according to the invention;

FIG. 6 represents a top view according to arrow F6 shown in FIG. 5;

fig. 7 shows a cross-section according to line VII-VII in fig. 6 on a larger scale;

fig. 8 shows, to the same scale, a cross section for a variant according to line VIII-VIII in fig. 6;

FIG. 9 shows a variation of FIG. 8 with a low edge region formed;

fig. 10 to 14 present variants in the same view as fig. 8;

fig. 15 shows a cross-section for modification according to the line XV-XV shown in fig. 5 on a larger scale;

FIG. 16 schematically illustrates some steps in another method according to the invention;

fig. 17 represents, on a larger scale, a cross section according to the line XVII-XVII shown in fig. 16;

Fig. 18 and 19 represent, on the same scale, a cross-section for modification according to the lines XVIII-XVIII shown in fig. 16;

fig. 20 shows a perspective view according to arrow F20 shown in fig. 19;

FIG. 21 schematically illustrates some steps in another method according to the invention;

fig. 22 represents a variant in a cross-section according to line XXII-XXII shown in fig. 5;

FIGS. 23 and 24 illustrate some alternative segmentation operations in perspective;

FIG. 25 shows the region indicated by F25 in FIG. 5 on a larger scale;

fig. 26 and 27 represent alternative ways of representing the region indicated with F26 in fig. 25;

FIG. 28 shows a cross section according to line XXVIII-XXVIII shown in FIG. 27;

fig. 29 schematically shows some steps in another method according to the invention;

FIG. 30 shows a cross section according to line XXX-XXX in FIG. 29 on a larger scale;

FIGS. 31 and 32 schematically illustrate some steps in another method according to the invention; and

fig. 33, 34a and 34b show various embodiments of a cutting tool for use in another method according to the invention.

Detailed Description

Fig. 1 shows some steps in a method for manufacturing a decorative panel 1.

As shown in fig. 2 to 4, the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the substrate is a substrate comprising a thermoplastic material, wherein the substrate and decorative top layer are obtained from a larger material 4 by a dividing operation S1, characterized in that the panel 1 comprises a low edge region 6 at both upper edges 5 of a pair of opposite side edges, wherein the low edge region 6 is obtained before or during the dividing operation S1.

The dividing operation S1 comprises performing a cutting operation, releasing at least the substrate 2 of the panel 1 from the larger material 4 at least two opposite edges.

The cutting operation forms opposite cutting edges 7 for releasing said at least two opposite edges, wherein said opposite cutting edges 7 are positioned at mutually different distances D1-D2 from said upper edge 5 of said panel 1. The distance D2 at the upper edge 5 where the panel is to be provided with the groove 9 is larger than the distance D1 at the upper edge 5 where the panel is to be provided with the tongue 10. The tongue 10 and the groove 9 form part of a coupling device with which two such panels can be coupled at the respective edges such that they lock together in a horizontal direction H perpendicular to the respective edges and in the plane of the panel 1, and in a vertical direction V perpendicular to the plane of the panel.

The decorative top layer 3, preferably at least its printed pattern 8, continues uninterruptedly from the entire upper surface of the panel 1 to the low edge area 6 and over the low edge area 6.

The lower edge regions 6 at the opposite upper edges 5 extend to each other to the same or substantially the same depth measured perpendicular to the upper edges 5 and/or to the same or substantially the same horizontal distance measured perpendicular to the upper edges. The low edge region 6 is formed as a chamfer, in this case a slightly curved chamfer.

The low edge regions 6 at the opposite upper edges 5 may extend to the same or substantially the same depth as each other, said depth being between 0.4mm and 0.6mm below the entire upper surface of the panel 1. Preferably, the depth may be about 0.4mm or 0.5mm.

In an embodiment, at least two substrates and/or top layers for the respective panels 1 are obtained from said larger material 4.

The substrate 2 is compressed or deformed at the location of the low edge region 6. The bottom of the substrate 2 remains undeformed. In this case, the bottom of the substrate 2 is supported by the support means 11 for this purpose.

The substrate 2 and/or the decorative top layer 3 exhibit the following properties:

the substrate 1 comprises a layer 12 of foamed central material, for example a closed-cell foam of thermoplastic material (for example PVC); this central material layer 12 is adjacent to a denser and/or less foamed material layer 13 (the so-called outer shell layer) at its bottom and top surface;

the substrate 1 comprises one or more voids at least at a position vertically below said low edge region; in this case, the void is formed by cells of the foam, but according to a variant not shown, the void may be structural, for example a cavity formed during extrusion of the substrate 2, for example similar to that further shown in fig. 11.

The decorative layer 3 comprises a material with a shore a hardness of less than 80 and preferably greater than 20. In this case, such a material is usable at least in the backing layer 14. This results in a smoother compression in the low edge region 6.

As shown, the low edge region 6 is formed simultaneously with the splitting operation S1 or in the process, for example according to the first possibility of forming a low edge region mentioned in the introduction.

Preferably, as shown here, the dividing operation S1 includes:

-providing said larger material 4 in a dividing device 20;

recessing the larger material 4 at the location of the upper edge 5 so as to at least partially form the low edge region 6;

-releasing the substrate 2 and the decorative top layer 3 from the larger material 4 by a cutting operation with a cutting tool 15, for example by a knife forced into and through the larger material 4.

The recessing is achieved by means of a mould or mould parts 16 which are pressed down on the substrate 2 and the decorative top layer 3. The mould or mould parts 16 are joined with the substrate 2 and the decorative layer 3 at the beginning of the cutting operation and preferably remain joined at the end of the cutting operation. For this purpose, the die or die part 16 is movable relative to the cutting tool 15. Preferably, the mould or mould part 16 is substantially stationary during the cutting operation, i.e. when the cutting tool 15 is moved into and through the substrate 2 and the decorative layer 3.

As shown herein, the singulation operation includes a cutting operation, more specifically a stamping operation, i.e., an operation in which a fixed (i.e., non-rotating) cutting blade or knife is pressed down into the larger material 4 to be cut, and through the larger material 4 to be cut.

In the embodiment of fig. 1 to 4, the substrate 2 comprises at least one plate or layer comprising a thermoplastic material, preferably a filled synthetic composite comprising a thermoplastic material and a filler, preferably a mineral filler, such as sand, talc, chalk or other forms of CaCO3. The decorative top layer 3 comprises a motif formed by the printed pattern 8. According to an alternative, wood veneers may be used to form the motif. The printed pattern 8 is provided on a carrier layer 17 and a transparent wear layer 18 is applied on top of said printed pattern 8.

Preferably, the wear layer 18 comprises protrusions 19 applied or realized before said splitting operation S1. Said projections 19 preferably remain available in the low edge region 6 after the mould part 16 has been released.

In an embodiment, the decorative top layer 3 comprises at least, from bottom to top, a backing layer 14, a print carrier layer 17 and a transparent wear layer 18, preferably the backing layer 14 forming a major part of the thickness T of the decorative top layer 3, or as the case may be, at least 45% thereof. The substrate 2 is preferably a single-piece substrate, i.e. without an inner glue layer, and preferably forms a major part of the thickness T1 of the panel 1.

In an embodiment, the backing layer 14 is a thermoplastic layer of soft PVC (i.e., PVC with greater than 10phr plasticizer), which also includes filler.

One or more of the cutting tool 15 and/or the die or die portion 16 may be heated, but preferably is not heated.

It should further be noted that in the illustrated case of fig. 1 to 4, the deformation of the base 2 and the decorative layer 3, as well as the positioning of the coupling means in the decorative panel 1, is such that the contact surfaces 21-22 between the top of the tongue 10 and the bottom of the upper groove lip 23 are formed in the backing layer 14, while the lower groove lip 25 and the horizontal locking surfaces 24-24A on the bottom of the tongue 10 are formed in the base 2.

Fig. 5 to 7 represent an embodiment according to the second possibility mentioned in the introduction for forming the low-edge region 6. In this case, the low-edge region 6 is formed in line with the cutting operation before at least the cutting operation S1 of the substrate 2 is released from the larger material 4 at least two opposite edges. The low edge region 6 is formed by the structured roller 26 using a continuous forming operation. The roller 26 comprises at its circumference a mould part 16 which presses down or deforms the larger material 4 to create said low edge region 6. The roller 26 forms a low edge region 6, through which the larger material 4 is fed in the feed direction F. The forming operation S2 is arranged in correspondence with the extrusion operation S3 and the lamination operation S4 for forming the larger material 4.

The extrusion operation S3 includes a supply device 27 for supplying the raw material for the substrate 2 to the extruder 28. The raw material is extruded through a so-called flat die or slot die 29 into a flat web-shaped base material, for example having a width W of 1 to 2.1 meters, preferably about 1.3 meters, and a thickness T2 of 2 to 7mm, preferably 3 to 6mm, more preferably 3 to 5mm, even more preferably 3.5 to 4.5mm, preferably about 4 mm. In the lamination operation S4, one or more of the carrier layer 17, transparent abrasion layer 18, and backing layer 14 having the printed pattern 8 may be laminated to a mesh substrate material to form the larger material 4.

In an embodiment, an optional thickness calibration S5 may be performed on the extruded material by one or more rollers and/or calibration plates and/or heaters and/or coolers.

In an embodiment, before said forming operation S2, protrusions 19 are formed in at least said transparent wear layer 18 in an embossing operation S6. As shown herein, the printed pattern 8 represents a wood pattern and the protrusions 19 comprise indentations representing wood pores and/or wood grain lines. The indentations may be formed according to the printed pattern 8 to create a so-called registered embossing, as well as the natural appearance of the panel 1. It is of course not excluded to use other printed patterns 8, such as stones or fantasy patterns, wherein in this case corresponding indentations may also be applied, whether or not aligned with the printed patterns 8.

As shown in fig. 5 and 6, the projections 19 are formed by an embossing roller 30.

The larger material 4, in particular the decorative top layer 3, can be heated, for example, by means of an infrared or near-infrared radiator 31, before said embossing operation S6 and/or before said deforming operation S2. In some embodiments, the larger material 4 may be heated to a temperature between 160 ℃ and 190 ℃, preferably between 170 ℃ and 190 ℃, more preferably between 175 ℃ and 185 ℃. In certain embodiments, the larger material 4 may be heated to a temperature of about 180 ℃.

Whether or not in combination with such heating, the rolls 30 and/or 26 may be cooled by any other means than the larger material 4 and/or the decorative top layer 3, which may still be hot, or at least not heated.

However, it is also possible for the rolls 30 and/or 26 to be heated by other means than the larger material 4 and/or the decorative top layer 3, which may still be hot, for example by means of hot oil at a temperature above 40 ℃ or above 65 ℃. In this case, it may not be necessary to preheat the larger material 4 or in particular the decorative top layer 3.

Particularly in the case of the use of heated rolls 30 and/or heated rolls 26, it is preferred that the larger material 4 follows a curved path around the respective rolls 30-26 corresponding to an arc length L of at least 10 °. This is shown here in the case of an embossing roll 30, in which the larger material 4 follows a curved path around the embossing roll, corresponding to an arc length L of approximately 90 °.

It should be noted that the embossing roller 30 and/or the structured roller 26 forming at least the low edge region 6 is preferably paired with at least one counter roller 32-32'. Preferably, the at least one counter roll 32-32' has a rubber surface or mantle and/or has a surface or mantle with a shore a hardness of less than 80 at 23 degrees celsius (and even better between 60 and 80 at 23 degrees celsius). According to a preferred embodiment, the at least one counter roll has a rubber surface and/or has a surface with a shore a hardness of about 80 at 23 degrees celsius.

The cutting operation S1 is performed by a plurality of rotary cutting tools 15. In this case, the cutting tool 15 is included on the cutting roller 33. It is apparent that the cutting operation S1 shown here releases the substrate 2 from the larger material only at a pair of opposite edges. The cutting operation S1 is more specifically configured to form one or more cutting edges 7 in the feed direction F of the larger material 4.

The cutting tool 15 is positioned to form opposing cutting edges 7 at a fixed distance D1-D2 from the upper edge 5 of the trim panel 1. The position of the cutting tool 15 may be controlled or controlled in accordance with the upstream portion of the larger material (as indicated by arrow 34) and the sensor 35. The sensor may be a tactile and/or optical sensor.

The cutting tool 15 is provided with support means 11 by means of counter rollers 36. The counter roll may be provided with indentations matching the position of the cutting tool 15.

As indicated by the dashed line 37 in fig. 7, the larger material 4 may preferably be provided with a reference portion 38 prior to said dividing operation S1. In an embodiment, the reference portion 38 is formed as an indentation in the bottom of the larger material 4. To form the counter roll 32', a protrusion 39 for indenting the bottom of the larger material 4 may be provided, or separate means may be provided for achieving a recess, e.g. an indentation, in the bottom of the larger material 4.

The reference portion 38 is provided at a fixed distance D3 from the upper edge 5 and may be used in the cutting operation S1 to align the one or more cutting tools 15 such that the low edge region 6 is parallel to the one or more cutting edges 7 and preferably at a predetermined distance.

As shown here, the reference portion 38 is provided in a portion of the larger material 4 held in the finally obtained trim panel 1. According to a variant, the reference portion 38 may be provided in a so-called technical area 40, i.e. a portion of the larger material 4 that is to be removed in a subsequent operation, for example in a milling operation that forms a coupling device at the respective edge.

Fig. 8 and 9 show a variant in which the low-edge region 6 is formed by recessing the material at the edge of the pre-processed portion 41 of the larger material 4. The preparation of the portion 41 is performed from the top of the larger material 4 through the decorative top layer 3 into the substrate 2. In an embodiment, the pre-processing portion 41 comprises a lateral undercut 42 vertically below the remaining decorative top layer portion of the larger material 4.

As shown in fig. 9, in the forming operation S2, the walls 43 of the undercut 42 are closer to each other and may contact. The walls 43 may be adhered to each other by thermal fusion or by a separate glue (e.g. tetrahydrofuran glue) or by an additional (e.g. powdered) base material added to the pre-processing portion 41. The latter is an interesting embodiment when the base material comprises a thermoplastic material, such as polyvinyl chloride (PVC), polyethylene (PE), polyethylene terephthalate (PET) or polypropylene (PP), because this material can be made to adhere smoothly between the walls 43 by heating and subsequent cooling, forced cooling or cooling under hot conditions.

Fig. 10 and 11 show variants in which the substrate 2 comprises a void 44 at a position vertically below the low-edge region 6 to be formed or in the technical region 40. In the case of fig. 10, the void is formed by cells of foam portion 45 within substrate 2. In the case of fig. 11, the void is formed by a chamber 46 included in the substrate 2. Such a chamber 46 may have a maximum dimension D4 that is at least 20% of the undeformed thickness T2 of the substrate 2. In the case of fig. 10, as in the case of fig. 11, the substrate 2 is additionally formed as one or more solid material layers, in this case as a single solid material layer.

Fig. 12 shows another variant. In this case, the substrate 2 comprises a foam material portion 45 at the location of the low edge region 6 to be formed. More particularly, in this case, the foam material portion 45 may be obtained at the surface of the substrate 2.

Fig. 13 shows another variant. In this case, the substrate 2 comprises a recess 47 at the location of the low edge region 6 to be formed. The recess 47 comprises a powder material 48. The powder material 48 may conform to the shape of the low edge region 6 during the forming operation S2, such as by melting or otherwise flowing to conform to the mold portion 16. Preferably, the powder material 48 is subsequently cured to maintain the shape. As an alternative to powder materials, materials may be used which exhibit a liquid or pasty behaviour when forming the low edge region. Preferably, the filler material is a powder material 48 or other material having thermoplastic properties. Preferably, as the filler material, the same or similar material as the substrate 2 is used. In the case of substrates which are meant to be PVC, powders containing PVC may be used, but any other powder material containing thermoplastic may be used for this purpose.

Fig. 14 shows a further variant in which the substrate 2 comprises regions 49 of different material composition at the locations where the low-edge regions 6 are to be formed. In this case, the regions 49 extend from the bottom to the top of the respective material layers. In this case, the substrate 2 is formed as a single layer of material, and the region 49 extends from the bottom to the top of the substrate 2. Preferably, the material of region 49 exhibits one or a combination of two or more of the following properties:

The foaming nature of the material of region 49;

the extent of foaming of the material of the region 49 is higher than the properties of the material of the substrate 2 or of the corresponding material layer outside said region 49. Potentially, the material of the substrate 2 or of the corresponding material layer outside said region 49 is unfoamed;

the material of the region 49 has a lower density than the material of the substrate 2 or of the corresponding material layer outside said region 49. Preferably, the average density of the areas 49 is at least 100kg/m lower than the average density of the material of the substrate 2 or of the corresponding material layer outside the areas 49 ³ ；

The material of the region 49 comprises the nature of the filler, however the weight ratio of filler/thermoplastic material is smaller than in the case of the material of the substrate 2 or of the corresponding material layer outside said region 49. Preferably, the weight ratio of filler/thermoplastic material in the region is lower than 0.8, while the weight ratio of filler/thermoplastic material in the substrate 2 or the corresponding material layer outside the region is at least 1;

the material of the region 49 comprises the properties of the plasticizer, however the ratio expressed in phr (parts per hundred parts of resin) is higher than in the case of the material of the corresponding material layer or substrate 2 outside the region 49. Preferably, the plasticizer content in said region 49 is at least 5phr higher than the plasticizer content (if any) in the substrate 2 or corresponding material layer outside said region 49;

The material of the region 49 and the material of the substrate or the corresponding material layer outside the region 49 each comprise the properties of a thermoplastic material, preferably the same thermoplastic material, preferably a material selected from the list consisting of PVC, PP, PE and PET;

the material of zone 49 has the property of having a shore a hardness lower than 80, preferably lower than 20;

the material of the region 49 has a shore a hardness at least 10 lower than the material of the substrate 2 or the corresponding material layer outside the region 49;

the properties of the regions 49 and the respective material layers or the rest of the material of the substrate 2 have been obtained by coextrusion.

Fig. 15 shows a variant in which the substrate 2 has been preformed before the lamination step S4, at least partly in accordance with the low-edge region 6 to be formed. Such preforming may be achieved by using a suitable die instead of the slot die 29, or by suitably processing the extruded mesh substrate material.

Although fig. 8-15 have been described in connection with the method shown in fig. 5-7, it is clear that the use of the pre-processing portion 41, the void, the foam portion 45, the chamber 46, the area 49, the preformed substrate 2, or the powder material 48 may advantageously be combined with any of the methods of the present invention, such as with the method shown in fig. 1-4, or with the method further shown in fig. 16-20, or as shown in fig. 29-30.

It should further be noted that the substrate 2 or substrate material layer comprising the coextruded region 49 of different composition may be more widely used than would be used alone to achieve the low edge region 6. For example, such areas 49 may be practiced to create increased flexibility or mechanical strength at the edges to facilitate the quality of the coupling device to be machined therein, and/or to create increased water repellency or water resistance at the edges while keeping the material costs manageable. Thus, according to a first particular independent aspect, the invention also provides a method for manufacturing a decorative panel 1, said panel 1 comprising at least a substrate 2 and a decorative surface, wherein said method comprises at least the step of forming a material layer of said substrate 2 by extrusion, characterized in that said material layer comprises a region 49 of a material composition different from the material composition of said material layer outside said region 49. Preferably, a larger material 4 comprising the material layer is obtained, from which at least the substrate 2 of the trim panel 1 or the material layer thereof can be obtained by means of a dividing operation S1. It is clear that the decorative surface can be formed in a number of ways, for example with at least the printed pattern 8, whether or not provided on the carrier layer 17, and/or on the transparent wear layer 18 and/or the backing layer 14. It is further evident that the area 49 is preferably located at one or more edges of the trim panel 1. Preferably, the region 49 displays properties as listed above in connection with fig. 14. It is further evident that the embodiment substrate 2 of fig. 10 to 12 and 14 can be obtained by means of a method according to a particular independent aspect of the invention. Preferably, at least the part of the lower groove lip 25 and/or tongue 10 extending horizontally beyond the associated upper edge 5 is realized entirely in such a region 49. Preferably, the region 49 extends in a direction perpendicular to the upper edge at least a distance corresponding to the distance between the upper edges 5 of two adjacent panels 1 to be formed in the larger material 4. Preferably, at least one, and preferably both, of the pair of opposite edges of the trim panel are formed entirely of the material of said region 49. In the case of square or rectangular and oblong trim panels 1, a similar area 49 is preferably available at the other pair of opposite edges.

It should further be noted that the invention also relates in an independent manner to a decorative panel 1 or a larger material suitable for dividing the decorative panel 1, wherein said panel 1 comprises at least a substrate 2 and a decorative surface, wherein said substrate 2 comprises at least one material layer, characterized in that said material layer comprises a region 49 of a material composition different from the material composition of said material layer outside said region 49. The material composition of the region 49, its dimensions and location may further exhibit the characteristics as described above in relation to the first particular independent aspect, without the substrate 2 having to comprise a layer of material that has been obtained by extrusion. Preferably, the region 49 displays properties as listed above in connection with fig. 14.

Fig. 16 shows a method according to the invention. The method shown is a further embodiment of the second possibility mentioned in the introduction. Here, the low edge region 6 is formed before the cutting operation S1. In particular, in the lamination operation S4A, the print carrier layer 17, the transparent wear layer 18 and/or the backing layer 14 are laminated to form the decorative top layer 3 before the lamination of the obtained decorative top layer 3 to the substrate 2 in a subsequent lamination operation S4B. In said lamination operation S4A, a decorative top layer 3 as shown in fig. 17 is obtained, i.e. comprising at its surface a low edge region 6 with a transparent wear layer 18, while the opposite surface remains substantially flat or flat to allow a fluent lamination in said lamination operation S4A. In the embodiment of fig. 16, this is obtained by means of a forming operation S2 of the decorative top layer 3 by means of a structured roller 26 debossing before the laminating operation S4B.

Fig. 18 shows a variation of using a pre-structured backing layer 14. In this case, the availability of the structured roller 26 may still be of interest to obtain good lamination quality on the pre-structured backing layer 14. The pre-structured backing layer 14 comprises thinned sections 50 at least at the locations where said low edge regions are to be obtained.

Fig. 19 and 20 show another variant of using a backing layer 14 comprising a removal section 51 corresponding to the low edge region 6 to be formed. Such an embodiment is interesting in order to enable the formation of the low edge region 6 with a lower power or deformation. Fig. 20 clearly shows that the backing layer 14 is still a one-piece layer, despite the presence of the removal segment 50.

With respect to the variants of fig. 18 to 20, it should be noted that these backing layers 14 with thinning sections 50 and/or removal sections 51 may be provided in a prefabricated manner from rolls, or provided with the thinning sections 50 and/or removal sections 51 immediately before and in line with the lamination operation S4A, for example immediately or almost immediately before the lamination operation S4A, or between the unwinding operation and the lamination operation S4A

Fig. 21 shows a method for forming the low-edge region 6 mentioned in the introduction according to a third possibility. The larger material 4 comprising the substrate 2 and the decorative top layer 3 is formed by a pressing operation S4', wherein a plurality of prefabricated layers 17-18-14 are adhered to each other. In this case, the print carrier layer 17, the transparent abrasion layer 18 and the backing layer 14 are adhered to the substrate 2 by said pressing operation S4'. By the structured pressing element 52 coming into contact with the decorative top layer 3 to be formed, a low-edge region 6 is formed at the same time as the pressing operation S4'. In an embodiment, the backing layer 14 includes a removal section 51, which is similar or identical to that described in connection with fig. 19 and 20.

As indicated by dashed line 53, bottom platen 54 may be shaped to provide reference portion 38 in the bottom of larger material 4. Such reference portions may be similar to those shown in connection with fig. 7.

It is apparent that the pressing operation S4' uses a single-layer press as shown in fig. 21. Of course, as an alternative, not shown, a multi-layer press may be used, in which several stacks of one or more layers 14-17-18 of at least the substrate 2 and the decorative top layer 3 are then positioned on top of each other by means of one or more intermediate pressing elements 52 and pressed immediately.

Fig. 22 shows that the transparent wear layer 18 may be provided with thinned sections 50 corresponding in position to the low edge regions 6 to be formed. Such a transparent wear layer 18 may be used in conjunction with any of the methods described in the previous and following figures and/or introduction and claims. It is evident that such a transparent wear layer 18 with thinned sections 50 will at least partly accommodate the low edge region 6 with minimal deformation. The thinned section 50 may provide lower wear resistance at the surface of the low edge region 6. However, the inventors consider this to be of no significance, as the low edge region 6 is typically so small that it cannot walk on and is therefore less subject to wear and abrasion.

Fig. 23 shows that the reference portion 38 may be used to align the larger material 4 with the singulation operation S1 or the singulation device 20. In the embodiment of fig. 20, a single reference portion 38 is used for alignment. Here, the guiding means 38A is engaged with the reference portion 38. As in the case here, such a reference portion 38 is preferably available at the middle 20% of the width of the larger material 4. This limits the possible misalignment and is expected to be maximum if the outer trim panel 1 is divided. However, according to a preferred embodiment, it is possible to control or control the position of the cutting tool 15 based on the material portion of the larger material 4 in order to minimize potential misalignment in the width direction.

Fig. 24 shows an alternative in which multiple reference portions 38 are subsequently used to divide one trim panel at a time and/or to perform one cut at a time. Doing so may use the appropriate reference portion 38, preferably the reference portion 38 closest to the cut to be made, to realign multiple times. In the view of fig. 24, after the cut has been performed, the divided trim panel 1 is removed, the larger material 4 is moved in the direction of arrow 55 towards the observer and realigned using the reference portion 38A. Then, a subsequent cut is performed to divide out the next decorative panel 1.

Fig. 25 shows an enlarged view of the arrangement of the embossing roll 30, structured roll 26 and counter roll 32' of fig. 5. According to a variant, not shown, the embossing roller and the structured roller can exchange positions, i.e. a method in which the forming operation S2 is performed before and in correspondence with the embossing operation S6.

Fig. 26 shows an alternative arrangement for forming operation S2 itself. Here, the structured roller 26 is paired with a plurality of counter rollers 32A-32B-32C, and optionally with a belt 56 disposed on the counter rollers 32A-32B-32C. The larger material 4 here follows a curved path around the roller 26 corresponding to an arc length L of at least 100 °, in this case even 180 °.

Preferably, the pressure exerted on the larger material 4 at the location of the counter rolls 32A-32B-32C increases in the feed direction F. The contact at counter roll 32A is therefore preferably at a lower contact pressure than the contact at counter roll 32B, which in turn is preferably at a lower contact pressure than the contact at counter roll 32C. According to a variant or in combination therewith, the gap 57A-57B-57C between the counter roller 32A-32B-32C and the embossing roller 26 decreases in the feed direction F. The gap 57A at the location of the counter roll 32A is therefore preferably greater than the gap 57B at the counter roll 32B, which gap 57B in turn is preferably greater than the gap 57C at the counter roll 32C. The pressure exerted on the larger material 4 and/or the gaps 57A-57C-57B may be adjusted by changing the position of the respective counter rolls 32A-32B-32C, as indicated by the arrows in fig. 26.

Preferably, at least one of the plurality of counter rollers 32A-32B-32C has a rubber surface. Preferably, the first counter roller 32A in the feeding direction F has a rubber surface. Where a belt 56 is used, this preferably involves a steel belt that may or may not be heated.

Preferably, the structured roller 26 of the embodiment of fig. 26 is a heated roller, such as by hot oil or other fluid, heated at a temperature above 40 ℃ or above 65 ℃. Of course, other ways of heating the roll 26 are not precluded and it is also possible to heat the larger material 4 before it enters the gap between the first counter roll 32A and the structured roll 26. In this case, the structured roller 26 may be cooled by any other means than the larger material 4 and/or the decorative top layer 3, which may still be hot, or at least not heated.

The inventors have found that pairing the structured roller 26 and/or the embossing roller 30 with a plurality of (i.e. at least two) counter rollers 32A-32B results in a better replication or copying of the embossments of the embossing roller 30 and/or the structured roller 26 into the decorative top layer 3, in particular into at least the transparent wear layer 18. An increase in the contact pressure in the feed direction F and/or a decrease in the gap 56 in the feed direction F is beneficial for moving the material of the decorative top layer 3, for example at least the material of the transparent wear layer 18, and potentially the material of the substrate 2 in case a deformed deep structure of the substrate 2 is required. The enhanced flow of material of the decorative top layer 3 and/or the substrate 2 results in a better conformation of the obtained embossments with the structure forming the low edge region 6 on the embossing roller 30 and/or the structured roller 26.

The above findings clearly show that according to a second particular independent aspect, the invention also relates to a method for manufacturing a decorative panel or a larger material suitable for being divided into a plurality of decorative panels, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the method comprises an embossing operation S2-S6, wherein at least the decorative top layer 3 is provided with indentations, characterized in that the embossing operation is performed by means of a roll 26-30 having protrusions for forming the indentations, and wherein the roll 26-30 is paired with at least two counter rolls 32A-32B-32C, preferably with at least three counter rolls 32A-32B-32C. In the latter case, the larger material and/or at least two, preferably at least three, counter rolls may be heated such that the larger material and the counter rolls contact each other at a contact temperature between 110 ℃ and 120 ℃, preferably between 110 ℃ and 115 ℃, more preferably about 114 ℃.

Preferably, according to said second particular independent aspect, the method further illustrates one or more of the following characteristics:

said embossing operations S2-S6 are performed on said larger material 4, wherein the larger material preferably corresponds to an arc length L of at least 100 °, preferably at least 150 °, along a curved path around the rollers 26-30;

-performing said embossing operations S2-S6 on said larger material 4 and the pressure exerted on the larger material 4 at the location of said at least two counter-rolls 32A-32B-32C increases in the feeding direction F of said larger material 4;

-performing the embossing operations S2-S6 on the larger material 4 and the gap 57 between the at least two counter-rolls 32A-32B-32C and the rolls 26-30 with the protrusions decreases in the feeding direction F of the larger material 4;

said rollers 26-30 comprising said protrusions are heated rollers, for example heated by hot oil or other fluid at a temperature higher than 40 ℃ or higher than 65 ℃;

said roller 30 comprises protrusions adapted to form indentations in the shape of wood pores or wood grains, and/or said roller 30 is used as an embossing roller in any of the methods described in the introduction and/or in the drawings;

said roll 26 comprises protrusions as mould parts 16 for forming the low edge area 6 and/or said roll 26 is used as a structured roll 26 for forming the low edge area 6 in any of the methods described in the introduction and/or in the figures.

It is clear that one or more of the counter rolls 32A-32B-32C may be provided with protrusions 39 for indenting the bottom of the larger material 4, similar to the protrusions 39 shown by fig. 7. In this way, the reference portion 38 may be formed at a fixed distance D3 from the upper edge 5, for example for positioning the larger material 4 in the cutting operation S1.

Fig. 27 and 28 show an alternative way of structuring roll 26 for use in the forming operation S2. Here, the mould part 16 is included on a belt 58 which is pressed down on the decorative top layer 3 and/or the substrate 2 by a roller 26A. The roller 26A is paired with a counter roller 32 at the bottom of the substrate 2. The position of the belt 58 can be controlled or controlled in the transverse direction as indicated by arrow 59, for example on the basis of the haptic and/or visual segments of the upstream portion of the decorative top layer 3.

Fig. 29 shows another method for forming the low-edge region 6, for example according to the second possibility as mentioned in the introduction. Here, the low edge region 6 is formed before the cutting operation S1.

As shown in fig. 29, the substrate 2 is provided in a continuous manner, for example, in this case by means of an extrusion operation S3. On top of the extruded substrate layer 2A an additional foamable layer 60 is applied, for example PVC comprising a foaming agent, such as azodicarbonamide. The foamable layer 60 is then provided with a foaming inhibitor by a printing operation, in this case by a roller 61. The foaming inhibitor is applied in a pattern corresponding to the area where less foaming is required, for example at least at the location corresponding to the low edge area 6 to be formed.

Downstream of the roller 61, in the feed direction F, foaming is initiated using a heat treatment, for example by means of an oven 62. In the case shown, foaming occurs after the lamination step S4 and before the dividing operation S1, which is not shown. Alternatively, the heat treatment may be performed with oven 62A prior to the lamination operation S4. As a further alternative, the heat treatment may be performed after or simultaneously with the dividing operation S1.

Fig. 30 shows a cross section of a larger material 4 obtained by the method of fig. 29. The substrate 2 comprising the extruded substrate layer 2A and the foam layer 60 is shaped according to the low edge region 6 at least partly due to the different foaming caused by the foaming inhibitor.

It is clear that according to variants, the embodiments described in connection with the figures showing the extrusion operation S3 may alternatively be practiced by other continuous operations, for example by one or more spreading operations and/or calendaring operations.

The trim panel 1 and the large-sized material 4 obtained by any of the methods of the present invention show technical features that have the advantages of the invention themselves, even when they are obtained by other methods. It is therefore evident that according to a third particular independent aspect, the invention further relates to a decorative panel 1 or a larger material 4 suitable for dividing a plurality of such decorative panels 1, which does not have to be obtained by one of the methods disclosed previously, characterized in that the decorative panel 1 or the larger material 4 comprises a substrate 2 and a decorative top layer 3, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the panel 1 comprises a low edge region 6 at least one upper edge 5 and preferably at both upper edges 5 of a pair of opposite side edges, wherein the decorative panel 1 or the larger material 4 exhibits one or more of the following properties:

The trim panel or larger material comprises at least one reference portion 38, which is preferably formed as a depression or indentation in its bottom. The reference portion 38 is preferably positioned closer to one of the upper edges 5 than the other. Such a reference portion 38 or trim panel 1 or larger material 4 may further exhibit the features described in connection with fig. 7, 21, 23 or 24, or features thereof described in the introduction, without having to be manufactured according to the methods disclosed in these figures or introduction. In particular, the positioning with respect to the upper edge 5 may be similar or identical;

the larger material 4 comprises at least one reference portion 38, which is located within the portion of material to be removed during said dividing or in a so-called technical area 40;

the base 2 comprises a void 44, a chamber 46 and/or a foam part 45 at a position vertically below said low edge region 6. Such voids 44, chambers 46, and/or foam portions 45 may further exhibit the features described in connection with fig. 10, 11, and/or 12, and/or features disclosed in this regard by way of introduction. In particular, the positioning of such voids 44, chambers 46 and/or foam portions 45 with respect to the upper edge 5 or lower edge region 6 may be similar or identical without having to manufacture the trim panel 1 or larger material 4 according to the methods disclosed in the other paragraphs;

A substrate 2 having the properties of the preceding paragraph, wherein the void 44, chamber 46 and/or foam portion 45 are crushed and/or deformed at a position vertically below the low edge region 6;

the substrate 2 or a material layer within said substrate 2 comprises a region 49 having a different material composition than said substrate 2 or material layer outside said region 49. Preferably, such regions 49 further exhibit one or more of the properties described in connection with fig. 14 and/or the first particular independent aspect of the invention.

The substrate 2 comprises a thinned section 50, for example as further described in connection with fig. 15;

the decorative top layer 3 comprises a print carrier layer 17 and/or a transparent wear layer 18 and/or a backing layer 14. Preferably, at least one of the layers comprises a thinned section 50 and/or a removed section 51, for example as further described in connection with any of fig. 18-20 and 22;

the decorative top layer 3 continues uninterruptedly from the entire upper surface of the decorative panel to the low edge region 6 and over the low edge region 6;

the substrate 2 comprises locally, underneath or immediately underneath said low edge area, glue or thermoplastic material. Such an embodiment may be obtained, for example, by the method described in connection with fig. 9 or fig. 13.

It is clear that a trim panel 1 or a larger material 4 with any of the above-mentioned technical features has the advantage that it can be manufactured with less required power and/or with increased accuracy and/or form a more realistic imitation of a chamfer product or other product with a low edge area 6.

With reference to the figures and/or any of the above independent aspects repeated, said substrate 2 may comprise at least one plate or layer comprising a thermoplastic material, preferably a filled synthetic composite comprising a thermoplastic material and a filler, preferably a mineral filler, such as sand, talc, chalk or other forms of CaCO3.

Preferably, said decorative top layer 3 comprises a motif, preferably formed by a printed pattern 8. The decorative top layer may comprise a carrier layer 17 on which the printed pattern 8 is provided and a transparent wear layer 18 applied on top of the printed pattern 8. The carrier layer may be a thermoplastic foil, preferably a PVC foil, a paper layer or a wood veneer. Preferably, the wear layer 18 is a thermoplastic foil, preferably a PVC foil. In some embodiments, the decorative top layer may have a thickness of between 0.06mm and 0.08mm, preferably about 0.07mm. In some embodiments, the wear layer 18 may have a thickness of between 0.25mm and 0.60mm, more preferably about 0.30mm or about 0.55mm. Most preferably, the thickness of the wear layer 18 is about 0.30mm.

According to some embodiments, the decorative top layer comprises a backing layer 14, wherein the backing layer preferably forms a major part of the thickness T of the decorative top layer 3, or at least 45% thereof. The decorative top layer 3 can be assembled from the backing layer, the print carrier layer and the wear layer by means of thermal lamination, i.e. preferably without a separate glue layer between the layers. Preferably, the decorative top layer 3, or at least the bottom layer thereof, is also connected to the substrate 2 by thermal lamination, i.e. without a separate glue layer. However, it is not excluded that the decorative top layer 3 or at least the bottom layer thereof is glued to the substrate 2.

Furthermore, it should be noted that the use of counter-rolls 32-32 'with soft and/or rubber surfaces paired with the embossing roll 30 or the structured roll 26 to form low edge areas results in a better reproduction of the embossing roll or the structured roll's embossments in the decorative top layer 3 and/or the substrate 2. This is especially the case in the practice of hot embossing, i.e. in the case where the embossing roller 30 and/or the structured roller 26 are heated. It is therefore evident that according to a fourth particular independent aspect the invention is a method for manufacturing a decorative panel or a larger material suitable for being divided into a plurality of decorative panels 1, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the method comprises an embossing operation S2-S6, wherein at least the decorative top layer 3 is provided with indentations, characterized in that the embossing operation S2-S6 is performed by means of a roller 26-30 having protrusions for forming the indentations, and wherein the roller 26-30 is paired with at least one counter roller 32-32' -32A-32B-32C having a rubber surface and/or a surface having a shore a hardness of below 80 at 23 degrees celsius (even better between 60 and 80 at 23 degrees celsius). According to a preferred embodiment, the at least one counter roll has a rubber surface and/or has a surface with a shore a hardness of about 80 at 23 degrees celsius. Preferably, the method of the fourth particular independent aspect is further characterized in that said rollers 26-30 with said protrusions are heated rollers heated at a temperature above 40 ℃ or above 65 ℃ for example by means of hot oil or other fluid. Furthermore, the method of the fourth particular independent aspect may exhibit one or a combination of two or more of the following features:

The roller 30 comprises protrusions adapted to form indentations in the shape of wood pores or wood grains;

said roller 26 comprises a protrusion as a mould part 16 for forming the low edge area 6;

said embossing operations S2-S6 are performed on said larger material 4 and the larger material 4 follows a curved path around the roller 26 corresponding to an arc length L of at least 100 °, preferably at least 150 °;

the method further shows the characteristics of the second particular independent aspect and/or of the preferred embodiments thereof;

the roller with the protrusions is used as embossing roller 30 or structured roller 26 in any of the methods described in the introduction and/or in the figures.

Fig. 31 and 32 schematically show a method for manufacturing a decorative panel 1, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the substrate 2 is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate 2 and/or the decorative top layer 3 is obtained from a larger material 4 by a dividing operation S1, and wherein the dividing operation S1 is performed to divide the larger material 4 into slabs comprising a single panel 1 or more than one panel 1 in a direction transverse to the feeding direction of the larger material 4. As shown, the panel 1 may optionally comprise a plurality of low edge regions at least one and preferably at both upper edges of a pair of opposite side edges, wherein the low edge regions are obtained before or during the splitting operation S1. The dividing operation S1 may comprise performing a cutting operation, releasing at least the substrate 2 from the larger material 4 at least two opposite side edges. The formed blank may comprise a single panel 1 or more than one panel 1. In the latter case, the slab comprising more than one panel 1 may be further divided into slabs comprising individual panels by a secondary dividing operation.

As shown in fig. 32, the dividing operation S1 may include a cutting operation, more specifically a punching operation, that is, an operation in which a fixed (i.e., non-rotating) cutting blade or knife 63 is pressed down to the material 4 to be cut, into the material 4 to be cut, and through the material 4 to be cut. Alternatively, in fig. 31, the dividing operation S1 comprises a non-fixed cutting operation, i.e. by using a roller 64 comprising knife-shaped protrusions 65 oriented transversely to the feeding direction of the larger material 4. By the rolling movement of the roller 64, the knife-shaped protrusion 65 is thus intermittently engaged and disengaged with the larger material 4 in order to divide the larger material 4 into slabs comprising a single panel 1 or more than one panel 1.

The low edge region may be formed simultaneously with the dividing operation S1, i.e., during the dividing operation, or almost simultaneously with the dividing operation S1. In particular, fig. 31 and 32 show a segmentation step S1 comprising:

-providing said larger material 4 in a dividing device;

-recessing the larger material 4 at the location of the upper edge so as to at least partially form the low edge region;

-releasing the substrate 2 and/or the decorative top layer 3 from the larger material 4 by a cutting operation with a cutting tool, for example by a cutting blade or knife 63, or by a roller 64 comprising a knife-shaped protrusion 65.

The recessing may be performed by means of a mould or mould part which is pressed down on the substrate 2 and/or the decorative top layer 3. In particular, the mould or mould part may be engaged with the substrate 2 and/or the decorative layer 3 at the beginning of the cutting operation and preferably still engaged at the end of the cutting operation. In case the mould or mould part is engaged with the larger material at least during a part of said cutting operation, a corresponding low edge region is formed at least partly simultaneously with the dividing operation S1 or during the dividing operation S1.

Fig. 34a additionally shows that, particularly in the case of a cutting tool involving a cutting blade or knife 63, the die or die portion 66 may be formed as a single entity with the cutting blade or knife 63. Alternatively, as shown in fig. 34b, the die or die portion may be formed as a separate entity 67 from the cutting blade or knife 63, wherein the cutting blade or knife 63 is movable relative to the die or die portion 67. Although not explicitly shown in fig. 34a and 34b, the cutting blade or knife 63 and the die or die portion 67, which are formed together or as separate entities, may be configured to allow positioning of the opposing cutting edges at mutually different distances from the upper edge of the panel.

Fig. 33 alternatively shows that when the cutting tool involves a roller 64 comprising a knife-shaped protrusion 65, the mould or mould part may be formed as a second protrusion 66 on the roller 64, comprised on at least one side, preferably on both sides, of the knife-shaped protrusion 65. Although not explicitly shown in fig. 33, the knife-shaped protrusion 65 and the second protrusion 66 on the roller 64 may be configured to allow positioning of the opposing cutting edges at mutually different distances from the upper edge of the panel.

The invention is in no way limited to the embodiments described above, but such a method, decorative panels and larger materials may be implemented according to several variants without departing from the scope of the invention.

Claims

1. Method for manufacturing a decorative panel, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate 2 and/or the decorative top layer 3 are obtained from a larger material 4 by a dividing operation S1, characterized in that the panel 1 comprises a low edge region 6 at least one upper edge of a pair of opposite side edges, preferably at two upper edges 5, wherein the low edge region 6 is obtained before or during the dividing operation S1.

2. The method according to claim 1, characterized in that the splitting operation S1 comprises the steps of: a cutting operation is performed to release at least the substrate 2 from the larger material 4 at least two opposite edges.

3. The method according to claim 2, wherein the cutting operation forms opposing cutting edges 7 to release the at least two opposing edges, wherein the opposing cutting edges are positioned at mutually different distances D1-D2 from the upper edge 5 of the panel.

4. Method according to any one of the preceding claims, characterized in that the low edge region 6 is formed simultaneously, almost simultaneously or during the splitting operation S1.

5. Method according to any one of the preceding claims, characterized in that the splitting operation S1 comprises the following steps:

-providing said larger material 4 in a dividing device;

releasing the substrate 2 and/or the decorative top layer 3 from the larger material 4 by a cutting operation with a cutting tool 15, for example by a knife which is forced into and through the larger material.

6. The method according to claim 5, characterized in that the recessing step is performed by pressing down on the mould or mould parts 16 on the substrate 2 and/or the decorative top layer 3.

7. Method according to claim 6, characterized in that the mould or mould parts 16 are joined with the base substrate 2 and/or the decorative top layer 3 at the beginning of the cutting operation and preferably remain joined at the end of the cutting operation.

8. A method according to claim 6 or 7, characterized in that the mould or mould parts 6 are movable relative to the cutting tool.

9. Method according to any one of claims 6 to 8, characterized in that the mould or mould parts 6 are substantially stationary during the cutting operation, i.e. when the cutting tool 15 is moved into and through the substrate 2 and/or the decorative top layer 3.

10. Method according to any one of the preceding claims, characterized in that the dividing operation S1 comprises a cutting operation, more particularly a punching operation, i.e. an operation in which a fixed, i.e. non-rotating, cutting blade or knife is pressed down into the material to be cut, and through the material to be cut.

11. A method according to any one of claims 2 to 3, characterized in that the low edge region 6 is formed in correspondence with the cutting operation or the singulation operation S1 that releases at least the substrate 2 from the larger material 4 at least two opposite edges, preferably before the cutting operation or the singulation operation.

12. The method according to claim 11, characterized in that the low edge area 6 is formed by one or more structured rollers and/or by embossing one or more strips of the larger material 4.

13. Method according to claim 11 or 12, characterized in that the cutting operation or the singulation operation S1 is formed by a plurality of cutting tools 15, preferably rotating.

14. The method according to claim 13, wherein the cutting tool is positioned to form opposing cutting edges 7 at a predetermined distance D1-D2 from the upper edge 5 of the panel 1.

15. The method according to claim 14, characterized in that the position of the cutting tool 15 is controlled based on the upstream portion of the larger material 4.

16. The method according to any one of claims 11 to 15, characterized in that the method further comprises the steps of: the larger material 4 comprising said substrate 2 and/or said decorative top layer 3 is provided by a continuous operation, which preferably comprises one or more extrusion operations S3, spreading operations, pressing operations and/or lamination operations S4.

17. Method according to claim 16, characterized in that the low edge region 6 and the cutting operation or the dividing operation S1 are performed in correspondence with the step of providing the larger material 4.

18. A method according to any of the preceding claims, characterized in that the low edge area 6 is formed by recessing material at the edge of the pre-processed portion 41 of the larger material 4.

19. The method according to claim 18, characterized in that the pre-processing portion 41 is performed by entering at least into the substrate 2 from the top of the larger material 4.

20. The method according to claim 18 or 19, wherein the pre-processing portion 41 comprises an undercut 42.

21. The method according to any one of claims 11 to 17, further comprising the step of: a larger material 4 is provided comprising at least the substrate 2, wherein the substrate 2 is provided with a lowered substrate area at the location of the low edge area 6 before the decorative top layer 3 is applied to the substrate 2.

22. The method according to any one of claims 11 to 17, further comprising the step of: a larger material 4 is provided comprising at least the substrate 2, wherein a decorative top layer 3 is applied to the substrate 2, wherein the decorative top layer 3 or a part thereof comprises a structure before it is applied to the substrate 2.

23. The method according to claim 22, characterized in that the structure of the decorative top layer 3 or the corresponding part 3 thereof comprises the low-edge region 6.

24. The method according to claim 22 or 23, characterized in that the decorative top layer 3 comprises a plurality of layers 14-17-18 and comprises a motif.

25. The method according to claim 24, characterized in that the layer 14 located under the pattern comprises thinned portions 50, removed portions 51 or openings, which substantially correspond to the position or configuration of the low edge region 6.

26. A method according to claim 24 or 25, characterized in that at least two, preferably all of the layers 14-17-18 are laminated to each other before applying them to the substrate 2.

27. A method according to any one of claims 1 to 3, characterized in that the method further comprises the steps of: the larger material 4 comprising said substrate 2 and/or said decorative top layer 3 is provided by a pressing operation in which a plurality of prefabricated layers 14-17-18 are adhered to each other.

28. The method according to claim 27, wherein the low edge region 6 is formed simultaneously with the pressing operation.

29. Method according to claim 27 or 28, characterized in that at least one of the prefabricated layers comprises a thinned section 50 and/or a removed section 51, preferably at least at the location where the low edge region 6 is obtained.

30. The method according to claim 29, wherein said at least one of said preformed layers 14-17-18 is a thermoplastic layer from which segments have been removed by a cutting operation, more particularly by a stamping operation.

31. The method of claim 30, wherein the at least one of the preformed layers is a single piece layer.

32. Method according to any one of the preceding claims, characterized in that the larger material 4 is provided with a reference portion 38 before the dividing operation S1.

33. Method according to claim 32, characterized in that the reference portion is used for aligning the larger material 4 to the singulation operation S1 or part thereof, more particularly to one or more cuts performed in the singulation operation, or vice versa, i.e. wherein the reference portion 38 is used for aligning one or more cutting tools 15 performing the cuts to the larger material 4, or both.

34. The method according to claim 33, characterized in that the alignment is such that the low edge region 6 is parallel to one or more cuts performed in the splitting operation S1.

35. The method according to any one of claims 32 to 34, wherein the reference portion 38 comprises a dent or recess provided in the bottom of the larger material 4.

36. The method according to any one of claims 32 to 35, wherein the reference portion 38 comprises an edge of the larger material 4.

37. The method according to any one of claims 32 to 36, wherein the reference portion 38 comprises a visual or tactile marking obtainable at the side of the larger material 4 comprising the low edge region 6.

38. A method according to any one of claims 32 to 37, wherein the reference portion 38 is provided at a predetermined distance D3 from the upper edge 5 of the panel 1.

39. Method according to any one of claims 32 to 38, characterized in that the reference portion 38 cooperates with a stop or guiding tool 38A in the splitting operation S1.

40. The method according to any one of the preceding claims, characterized in that the decorative top layer 3 continues uninterruptedly from the entire upper surface of the panel 1 to the low edge region 6 and beyond it.

41. Method according to any of the preceding claims, characterized in that the low edge areas 6 at opposite upper edges extend to each other to the same depth measured perpendicular to the upper edge 5 and/or to the same horizontal distance measured perpendicular to the upper edge.

42. A method according to any of the preceding claims, characterized in that the low edge area 6 is formed as a chamfer.

43. Method according to any of the preceding claims, characterized in that at least two substrates 2 and/or top layers 3 for the respective panels 1 are obtained or obtainable from the larger material 4.

44. A method according to any of the preceding claims, characterized in that the substrate 2 is compressed or deformed at the location of the low edge region 6.

45. The method according to any one of the preceding claims, characterized in that the substrate 2 and/or the decorative top layer 3 exhibit one of the following properties, or a combination of two or more:

the substrate 2 and/or the decorative top layer 3 comprise a layer of foam material, for example a closed-cell foam of thermoplastic material such as PVC;

-the substrate 2 and/or the decorative top layer 3 comprise one or more voids at least at a position vertically below the low edge region;

The substrate 2 and/or the decorative top layer 3 comprise a material having a shore a hardness lower than 80 and preferably higher than 20.

46. The method according to any of the preceding claims, wherein the substrate 2 comprises at least one of a plate or layer comprising magnesium oxychloride or magnesium sulfate.

47. The method according to any of the preceding claims, characterized in that the substrate 2 comprises at least one plate or layer containing thermoplastic material, preferably a filled synthetic composite comprising thermoplastic material and filler, preferably mineral filler, such as sand, talc, chalk or other forms of CaCO3.

48. Method according to any one of the preceding claims, characterized in that the decorative top layer 3 comprises a motif, preferably formed by a printed pattern 8 or a wooden veneer.

49. The method according to claim 48, characterized in that the decorative top layer 3 comprises a carrier layer 17, on which the printed pattern 8 is provided, and a transparent wear layer 18 is applied on top of the printed pattern 8.

50. The method according to claim 49, wherein the carrier layer 17 and/or the transparent wear layer 18 is a thermoplastic foil, preferably a PVC foil.

51. Method according to claim 50, characterized in that the decorative top layer 3 comprises, from bottom to top, at least a backing layer 14, a print carrier layer 17 and a transparent wear layer 18, preferably that the backing layer 14 forms a substantial part of the thickness T of the decorative top layer 3, or at least 45% thereof.

52. The method according to claim 51, characterized in that the backing layer 14 is a thermoplastic layer, preferably a thermoplastic layer of soft PVC, i.e. a thermoplastic layer of PVC with more than 10phr of plasticizer, and/or a thermoplastic layer of thermoplastic foam.

53. The method according to any one of claims 1 to 3 or 18 to 26 or 32 to 52, wherein the low edge region 6 is formed by one or more structured rollers 26 and/or by embossing one or more strips 58 of the larger material 4.

54. A method for manufacturing a decorative panel according to any one of claims 1 to 26, possibly in combination with any one of claims 32 to 52, or not, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the substrate 2 is a mineral-containing substrate and/or a thermoplastic-containing substrate 2, wherein the substrate 2 and the decorative top layer 3 are obtained from a larger material 4 by a dividing operation S1, characterized in that the method comprises a laminating operation S4 for providing at least a part of the decorative top layer 3, preferably a part with a printed pattern 8 on the substrate 2, wherein the laminating operation S4 is a continuous operation, wherein a respective part of the decorative top layer 3 is fed to the laminating operation S4 in a feeding direction F, and wherein the panel 1 is rectangular and oblong with its longitudinal edges oriented transversely to the feeding direction 1.

55. A method for manufacturing a decorative panel, wherein the panel 1 comprises at least a substrate 2 and a decorative surface, wherein the method comprises at least the steps of: the material layer of the substrate 2 is formed by extrusion, characterized in that the material layer comprises one or more regions 49 of a material composition different from the material composition outside the regions 49 of the material layer.

56. A method according to claim 55, characterized in that a larger material 4 comprising the extruded material layer is obtained, from which larger material at least the substrate 2 of the decorative panel 1 or at least the material layer of the substrate is obtained by means of a dividing operation S1.

57. The method according to claim 55 or 56, wherein the decorative surface comprises at least one printed pattern 8, whether or not provided on the carrier layer 17, and/or on the transparent wear layer 18 and/or the backing layer 14.

58. The method according to any one of claims 55 to 57, characterized in that the area 49 is located at one or more edges of the trim panel 1.

59. The method of any one of claims 55 to 58, wherein the region 49 exhibits one, or a combination of two or more of the following characteristics:

The foaming nature of the material of said region 49;

the material of the region 49 is foamed to a higher degree than the material of the substrate 2 or the corresponding material layer outside the region 49, wherein the material outside the region 49 is preferably unfoamed;

the material of the region 49 has a lower density than the material of the substrate 2 or the corresponding material layer outside the region 49;

the material of said region 49 comprises the property of a filler, however the weight ratio filler/thermoplastic material is smaller than in the case of the material of said substrate 2 or of the corresponding material layer outside said region 49;

the material of said region 49 comprises the properties of a plasticizer, however the ratio, expressed as phr (parts per hundred parts of resin), is higher than in the case of the material of the corresponding layer of material or of said substrate 2 outside said region 49;

both the material of the region 49 and the material of the substrate 2 or the corresponding material layer outside the region 49 comprise the properties of a thermoplastic material, preferably the same thermoplastic material, preferably a material selected from the list consisting of PVC, PP, PE and PET;

the material of said region 49 has the property of having a shore a hardness value lower than 80, preferably lower than 20;

60. A decorative panel or a larger material adapted to be divided into a plurality of decorative panels 1, wherein said panels 1 comprise at least a substrate 2 and a decorative surface, wherein said substrate 2 comprises at least one material layer, characterized in that said material layer comprises a region 49 having a material composition different from the material composition of said material layer outside said region 49.

61. A decorative panel or a larger material, characterized in that the decorative surface comprises at least one printed pattern 8, whether or not provided on a carrier layer 17, and/or a transparent wear layer 18 and/or a backing layer 14.

62. A decorative panel or larger material according to any one of claims 60 or 61, wherein the region 49 is located at one or more edges of the decorative panel 1.

63. A decorative panel or larger material according to any one of claims 60 to 62, wherein the region 49 exhibits one, or a combination of two or more of the following properties:

The foaming nature of the material of said region 49;

properties of the region 49 and the respective material layer or the remaining part of the material of the substrate 2 have been obtained by coextrusion, preferably by a method according to any of claims 54 to 58.

64. A trim panel or a larger material for division into a plurality of trim panels, characterized in that the trim panel 1 or the larger material 4 comprises a substrate 2 and a trim top layer 3, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the panel 1 comprises a low edge region 6 at least one upper edge of a pair of opposite side edges and preferably at two upper edges 5, wherein the trim panel 1 or the larger material 4 exhibits one or more of the following properties:

the decorative panel or the larger material comprises at least one reference portion 38, preferably formed as a depression or indentation at its bottom; the reference portion 38 is preferably positioned closer to one of the upper edges 5 than the other;

Said larger material 4 comprises at least one reference portion 38 located within the portion of material to be removed during said dividing;

the base 2 comprises a void 44, a chamber 46 and/or a foam portion 45 at a position vertically below the low edge region 6;

the substrate 2 comprises crushed or deformed voids 44, cavities 46 and/or foam parts 45 at a position vertically below the low edge region 6;

-the substrate 2 or a material layer within the substrate 2 comprises a region 49 having a different material composition than the substrate 2 or material layer outside the region 49;

-the substrate 2 comprises a thinned section 50;

said decorative top layer 3 comprises a print carrier layer 17 and/or a transparent wear layer 18 and/or a backing layer 14, preferably at least one of said layers comprises a thinned section 50 and/or a removed section 51;

the decorative top layer 3 continues uninterruptedly from the entire upper surface of the decorative panel onto the low edge region 6 and over the low edge region.

65. A method for manufacturing a decorative panel or a larger material suitable for being divided into a plurality of decorative panels 1, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the method comprises an embossing operation S2-S6, wherein at least the decorative top layer 3 is provided with indentations, characterized in that the embossing operation S2-S6 is performed by means of a roll 26-30 having protrusions for forming the indentations, and wherein the roll 26-30 is paired with at least two counter rolls 32A-32B-32C, preferably with at least three counter rolls 32A-32B-32C.

66. Method according to claim 65, characterized in that the embossing operations S2-S6 are performed on the larger material 4 and in that the larger material 4 travels along a curved path around the roller 26 corresponding to an arc length of at least 100 °, preferably at least 150 °.

67. Method according to claim 65 or 66, characterized in that the embossing operations S2-S6 are performed on the larger material 4 and in that the pressure exerted on the larger material 4 at the location of the at least two counter rolls 32A-32B-32C increases in the feed direction F of the larger material 4.

68. The method according to any one of claims 65 to 67, characterized in that the embossing operation S2-S6 is performed on the larger material 4 and in that the gap 57 between the at least two counter-rolls 32A-32B-32C and the roll 26-30 with the protrusions decreases in the feed direction F of the larger material 4.

69. The method according to any one of claims 65 to 68, wherein the roller 26-30 comprising the protrusions is a heated roller, for example heated by hot oil or other fluid at a temperature above 40 ℃ or above 65 ℃.

70. The method according to any one of claims 65 to 69, characterized in that the roll 30 comprises protrusions adapted to form indentations of the shape of wood pores or wood grains and/or is used as an embossing roll 30 in the method according to any one of claims 53 to 59.

71. The method according to any one of claims 65 to 70, characterized in that the roll 26 comprises protrusions as mold portions 16 for forming the low edge regions 6 and/or is used as structured roll 26 in the method according to any one of claims 53 to 59.

72. A method for manufacturing a decorative panel or a larger material suitable for being divided into a plurality of decorative panels 1, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the method comprises an embossing operation S2-S6, wherein at least the decorative top layer 3 is provided with indentations, characterized in that the embossing operation S2-S6 is performed by means of a roller 26-30 having protrusions for forming the indentations, and wherein the roller 26-30 is paired with at least one counter roller 32A-32B-32C having a rubber surface and/or a surface having a shore hardness a at 23 degrees celsius below 80, and better between 60 and 80 at 23 degrees celsius.

73. The method according to claim 72, wherein the rollers 26-30 with the protrusions are heated rollers, for example by hot oil or other fluid, at a temperature above 40 ℃ or above 65 ℃.

74. The method of any one of claims 72 or 73, wherein the roller 30 comprises protrusions adapted to form indentations of the shape of wood pores or wood grains.

75. The method of any one of claims 72 to 74, wherein the roller 26 comprises protrusions as the mould part 16 for forming the low edge region 6.

76. Method according to any one of claims 72 to 75, characterized in that the embossing operation S2-S6 is performed on the larger material 4, and in that the larger material 4 travels along a curved path around the roller 26 corresponding to an arc length L of at least 100 °, preferably at least 150 °.

77. The method of any one of claims 72 to 76, further exhibiting the features of claim 65, whether combined with the features of claims 67 and/or 68.

78. The method of any one of claims 72 to 77, further exhibiting the features of any one of claims 53 to 59, wherein the roller having the protrusions in the method of any one of claims 53 to 59 is used as an embossing roller 30 or a structured roller 26.

79. Method for manufacturing a decorative panel, wherein the panel 1 comprises a substrate 2 and a decorative top layer 3, wherein the substrate is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate 2 and/or the decorative top layer 3 is obtained from a larger material 4 by a splitting operation S1, wherein the splitting operation S1 comprises performing a cutting operation which releases at least the substrate 2 from the larger material 4 at least two opposite edges, and wherein the panel 1 comprises a low edge region 6 at least one upper edge of a pair of opposite side edges and preferably at two upper edges 5, wherein the low edge region 6 is obtained during the splitting operation S1 or is obtained almost simultaneously with the splitting operation S1, the splitting operation S1 comprising:

-providing said larger material 4 in a dividing device;

-releasing the substrate 2 and/or the decorative top layer 3 from the larger material 4 by means of a knife forced into and through the larger material, wherein the cutting operation forms opposing cutting edges 7 for the release at the at least two opposing edges, wherein the opposing cutting edges 7 are positioned at mutually different distances D1-D2 from the upper edge 5 of the panel.

80. The method according to claim 80, wherein the recessing step is performed by pressing down on the mould or mould parts 16 on the substrate 2 and/or the decorative top layer 3.

81. A method according to claim 81, wherein the mould or mould parts 16 are joined with the substrate 2 and/or the decorative top layer 3 at the beginning of the cutting operation and preferably remain joined at the end of the cutting operation.

82. The method of claim 81 or 82, wherein the mould or mould parts 6 are movable relative to the cutting tool.

83. A method according to any one of claims 81 to 83, wherein the mould or mould parts 6 are substantially stationary during the cutting operation, i.e. when the cutting tool 15 is moved into and through the substrate 2 and/or the decorative top layer 3.

84. The method according to any one of claims 80 to 84, wherein the splitting operation S1 comprises a cutting operation, more particularly a punching operation, i.e. an operation in which a fixed, i.e. non-rotating, cutting blade or knife is pressed down into, and through the material to be cut.

85. The method of any one of claims 80 to 85, wherein the low edge region 6 is formed by recessing material at the edge of the pre-processed portion 41 of the larger material 4.

86. The method according to any one of claims 80 to 86, wherein the larger material 4 is provided with a reference portion 38 prior to the splitting operation S1.

87. The method according to claim 87, wherein the reference portion is used for aligning the larger material 4 to the singulation operation S1 or a part thereof, more particularly to one or more cuts performed in the singulation operation, or vice versa, i.e. wherein the reference portion 38 is used for aligning one or more cutting tools 15 performing the cuts to the larger material 4, or both.

88. The method according to any one of claims 80 to 88, wherein the decorative top layer 3 continues uninterruptedly from the entire upper surface of the panel 1 to the low edge region 6 and beyond the low edge region.

89. The method of any one of claims 80 to 89, wherein the low edge regions 6 at opposite upper edges extend to each other to the same depth measured perpendicular to the upper edge 5 and/or extend the same horizontal distance measured perpendicular to the upper edge.

90. The method according to any one of claims 80 to 90, wherein at least two substrates 2 and/or top layers 3 for respective panels 1 are obtained or obtainable from the larger material 4.

91. The method according to any one of claims 80 to 91, wherein the substrate 2 is compressed or deformed at the location of the low edge region 6.

92. The method according to any one of claims 80 to 92, wherein the substrate 2 and/or the decorative top layer 3 exhibit one, or a combination of two or more, of the following properties:

93. Method according to any one of claims 80 to 93, wherein the substrate 2 comprises at least one sheet or layer, preferably a filled synthetic composite, comprising thermoplastic material and filler, preferably mineral filler, such as sand, talc, chalk or other forms of CaCO3, and wherein the decorative top layer 3 comprises a motif, preferably formed by a printed pattern 8 or a wood veneer.

94. Method for manufacturing a decorative panel, wherein the panel (1) comprises a substrate (2) and a decorative top layer (3), wherein the substrate (2) is a mineral-containing substrate and/or a thermoplastic-containing substrate, wherein the substrate (2) and/or the decorative top layer (3) is obtained from a larger material (4) by a splitting operation (S1), and wherein the splitting operation (S1) is performed to split the larger material (4) into slabs comprising a single panel (1) or more than one panel (1) in a direction transverse to the feeding direction of the larger material (4).

95. The method according to claim 95, wherein the slab comprising more than one panel (1) is further divided into slabs comprising a single panel (1) by a secondary dividing operation.

96. Method according to claim 95 or 96, wherein the panel (1) comprises a low edge region (6) at least one and preferably at both upper edges (5) of a pair of opposite side edges, wherein the low edge region (6) is obtained before, during or almost simultaneously with the splitting operation (S1).

97. The method according to claim 97, wherein the low edge region (6) is obtained during the splitting operation (S1) or almost simultaneously with the splitting operation (S1).

98. The method according to any one of claims 95 to 98, wherein the splitting operation (S1) comprises the steps of: -a cutting operation with a cutting tool to release at least the substrate (2) from the larger material (4) at least two opposite side edges.

99. The method according to any one of claims 97 to 98, wherein the splitting operation (S1) comprises the steps of: -a cutting operation with a cutting tool to release at least the substrate (2) from the larger material (4) at least two opposite side edges, wherein the opposite cutting edges are positioned at mutually different distances from the upper edge (5) of the panel (1).

100. The method according to any one of claims 95 to 100, wherein the dividing operation (S1) comprises a fixed cutting operation, more particularly a punching operation, i.e. an operation in which a fixed, i.e. non-rotating, cutting blade or knife (63) is pressed down into, into and through the material to be cut, and is oriented transversely with respect to the feed direction of the larger material (4).

101. The method according to any one of claims 95 to 100, wherein the dividing operation (S1) comprises a non-stationary cutting operation, i.e. an operation of a non-stationary, i.e. rotating, roller (64), the roller (64) comprising a knife-shaped protrusion (65), the protrusion (65) being intermittently engaged with the material to be cut by rotation of the roller, and being oriented transversely with respect to the feeding direction of the larger material (4).

102. The method according to any one of claims 96 to 102, wherein the secondary dividing operation comprises a cutting operation with a cutting tool, at least releasing the substrate (2) from the blank comprising more than one panel (1) at least two opposite side edges, wherein the opposite cutting edges are positioned at mutually different distances from the upper edge (5) of the panel (1).

103. The method according to any one of claims 96 to 103, wherein the secondary splitting operation comprises a fixed cutting operation, more particularly a stamping operation, i.e. an operation in which a fixed, i.e. non-rotating, cutting blade or knife is pressed down into a slab comprising more than one panel (1), into the slab, and through the slab.

104. The method according to any one of claims 96 to 103, wherein the secondary singulation operation comprises a non-stationary cutting operation, more particularly a sawing operation, i.e. an operation in which a rotating cutting blade or knife is moved into and through a slab comprising more than one panel (1).

105. The method according to any one of the preceding claims 95 to 105, wherein the splitting operation (S1) comprises:

-providing the larger material (4) in a dividing device;

-recessing the larger material at the location of the upper edge (5) so as to at least partially form the low edge region (6);

-releasing the substrate (2) and/or the decorative top layer (3) from the larger material (4) by a cutting operation with a cutting tool, for example by being pressed down into the larger material, into the larger material and through a cutting blade or knife (63) of the larger material, or by a roller (64) comprising a knife-shaped protrusion (65), the protrusion (65) being intermittently engaged with the larger material (4) by rotation of the roller (64).

106. The method according to any one of claims 97 to 106, wherein the low edge region (6) is obtained by recessing the larger material (4) by means of a mould or mould parts at the location of the upper edge (5).

107. The method according to claim 107, wherein the mould or mould parts are joined with the substrate (2) and/or the decorative top layer (3) at the beginning of the dividing operation (S1) and preferably remain joined at the end of the dividing operation (S1).

108. The method according to any one of claims 97 to 108, wherein the decorative top layer (3) continues uninterruptedly from the entire upper surface of the panel (1) to the low edge region (6) and beyond the low edge region.

109. The method according to any one of claims 97 to 109, wherein the low edge regions (6) at opposite upper edges extend to each other to the same depth measured perpendicular to the upper edge (5) and/or to the same horizontal distance measured perpendicular to the upper edge.

110. The method according to any one of claims 97 to 110, wherein the substrate (2) is compressed or deformed at the location of the low edge region (6).

111. The method according to any one of the preceding claims 95 to 111, wherein the substrate (2) and/or the decorative top layer (3) exhibit one, or a combination of two or more, of the following properties:

-the substrate (2) and/or the decorative top layer (3) comprise a layer of foam material, for example a closed-cell foam of thermoplastic material such as PVC;

-the substrate (2) and/or the decorative top layer (3) comprise one or more voids at least at a position vertically below the low edge region;

-the substrate (2) and/or the decorative top layer (3) comprise a material having a shore a hardness lower than 80 and preferably higher than 20.

112. The method according to any one of the preceding claims 95 to 112, wherein the substrate (2) comprises at least one sheet or layer, preferably a filled synthetic composite, comprising a thermoplastic material and a filler, preferably a mineral filler, such as sand, talc, chalk or other forms of CaCO3, and wherein the decorative top layer (3) comprises a motif, preferably formed by a printed pattern (8) or a wooden veneer.