EA041190B1 - METHOD OF MANUFACTURING PANELS FROM PLATE, PRESS PLATE, METHOD OF MANUFACTURING PLATE AND PLATE - Google Patents

Description

Technical field

The present invention is directed to a method for manufacturing board panels. These panels are made from a plate by cutting it along predetermined lines. The board contains a base material and is laminated with a layer of laminating material. On the surface, on which there is a layer of laminating material, there is at least one embossed area, which runs rectilinearly over the entire surface. These embossed areas are used to cut the slab. After cutting, pairs of mechanical locking means are milled on opposite edges of the raw boards. In accordance with the present invention, the embossed area has a well-defined width to allow for deviations from the ideal cutting plane when cutting the board to form panels. In addition, the present invention relates to a pressure plate that allows the production of boards with well-defined embossed areas. In addition, the present invention discloses a method for manufacturing a board having a particular defined embossed area. In addition, a plate for making panels is also described.

State of the art

The classic sandwich panel manufacturing process involves creating a large slab of base material, decor (either impregnated paper or material printed on the base material) and a wear layer (usually a top layer and a layer containing e.g. corundum particles) as in top side, and on the substrate on the bottom side. All of these layers are then pressed together in a press at elevated temperatures and pressures, resulting in a large sandwich board. The press typically uses a pressure plate, which typically also serves to extrude a three-dimensional structure onto the top surface of the sandwich board. Such a structure may mimic, for example, the structure of a tree with growth rings, a tile pattern, and the like.

The large multi-layer board is then cut lengthwise and transversely into individual panels, which are then edge-milled again to form locking profiles thereon. Chamfered surfaces are conveniently milled together with the surfaces of the locking profiles.

However, milling is a time-, material-, and tool-intensive process and should therefore be avoided whenever possible.

Therefore, it is desirable to use a pressure plate to press the chamfers into the sandwich board so that these chamfers do not have to be milled later in the manufacturing process.

For example, document WO 2017/072657 A1 describes a floor panel with a substrate and a top layer of laminating material, having at one or more edges a lower edge region and characterized in that the layer of laminating material extends integrally from the actual top surface of the substrate over the lower edge region, at least to the point where the surface of said layer is located at a level in a horizontal plane that intersects the aforementioned substrate, and in that the substrate material at the location of the lower edge region has the same or lower density than that of the actual upper surface of the material substrates. Said patent application also discloses a method for manufacturing such floor panels.

EP 1691005 A1 describes floorboards consisting of a base material and a surface layer with curved edges, which are formed by compression of the base material.

Document WO 2017/001976 A1 describes a floor panel with a substrate and a decorative layer of wood veneer applied thereon with a thickness of 1 mm or less, characterized in that said substrate has an average density of more than 750 kg per cubic meter, and in that said decorative the layer is applied to the substrate by means of a thermosetting resin layer located between the substrate and the decorative layer. The invention also discloses a method for manufacturing such a floor panel in which a structured veneer surface can be obtained.

In addition, EP 1676720 A2 describes floor coverings consisting of rectangular sandwich panels containing a base material and a decorative embossed layer on the top side of the panels, said base material being made of wood ground into particles or fibers mixed with a binding agent, and may be such as medium density fibreboard (MDF) or high density fibreboard (HDF), these panels having on at least two opposite edges connecting means integral with the panels, so that several such panels can be connected to each other without play or practically without play, while these connecting means provide mutual locking in the direction perpendicular to the plane of the floor covering, as well as in the direction perpendicular to the edges in question and parallel to the plane of the floor covering, and the coverings are characterized in that the panels have at least on said edges near the top side, a chamfer passing through the decorative embossed layer and the base material, said chamfer being made of a decorative layer which is made as a separate layer.

Document WO 2010/0136717 A2 refers to panels in which the first panel has a first profile and the second panel has a second profile. These panels can be connected horizontally and vertically using the specified profiles.

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Technical task

All of the above panels are generally manufactured by cutting a large board having a base material and a decorative layer thereon into several panels. The cutting, for example, can be performed by straight-cutting the slab along predetermined cutting lines. The raw panels obtained are subjected to further processing, for example, in subsequent manufacturing steps, the connecting means are milled.

Especially in the case where, for aesthetic purposes, the board has embossings or chamfers that appear on the cut panels as a slanted edge, a perfect cutting of the board is necessary to avoid misalignment of these chamfers on the manufactured panels. For example, if a slab is cut along a cut line that does not exactly follow the ideal theoretical cut line (but, for example, at a slight angle and/or to it), the cut line will pass through several levels, making the panels unsuitable for the manufacture of an optically perfect floor. . In addition, top layers (such as, for example, a decorative layer, which can also perform technical functions such as protection against water penetration) can be destroyed, so that an incorrectly cut board loses its protection and/or functionality.

However, in the aforementioned cutting, it is sometimes impossible to completely avoid errors, especially in the case where the cutting means, such as for example a saw, has a systematic error, or when there is a random error when cutting the board (for example, when the board moves slightly during cutting).

Accordingly, it is an object of the present invention to provide panels which, for example, make it possible to produce an ideal floor covering even when systematic or random errors occur when cutting the slab from which said panels are made.

Detailed description of the invention

This object is solved, respectively, using the method made in accordance with claim 1 of the claims, the pressure plate made in accordance with claim 28 of the claims, the method for manufacturing the plate made in accordance with claim 47 of the claims, as well as the plate for the manufacture of panels, made in accordance with paragraph 55 of the claims. Clause 57 discloses panels made in accordance with the present invention. The respective dependent claims describe preferred embodiments.

In a first aspect, the present invention relates to a method for manufacturing panels from a board, comprising using a board containing a base material, laminated with a layer of laminating material on the surface of the board of the base material, forming a laminated surface of the board, and the board has at least one embossed area containing at least one embossing of the laminated surface, which extends in a straight line and over the entire surface of the board, and in the cross section, perpendicular to the direction of passage of each of the specified at least one embossing, the specified embossed area has transitions in each most remote section of the embossed area, where the transition from the surface occurs to the bottom of the embossed area, moreover, said transitions have a width and a part of the embossed area adjoins them, and the bottom of the embossed area is parallel to the surface of the plate, rectilinear cutting of the plate along the cutting line passing in each specified at least one embossed area, at one or more cutting stages, for the production of raw boards using a cutting tool having a cut width, milling on opposite edges of the raw boards of paired mechanical locking means, containing a first mechanical locking means having a first width, and a paired second mechanical locking means having a second width (l2), wherein said at least one embossed area has a total width that is the sum of the width of the cut, the first width of the first mechanical locking means, the second width of the second mechanical locking means, the width of the transitions, the width of the sacrificial treatment, and also manufacturing tolerance, and the specified manufacturing tolerance is calculated as 0.10-3.0 times the width of the cut.

In accordance with the proposed method, the embossed area has a selected width, which is the sum of the selected partial widths. The width of the cut corresponds to the width of the means used for cutting, for example the width of a saw blade when sawing a board.

In accordance with the present invention, at least one embossing extends in a straight line and over the entire surface of the board. Rectilinear embossing means that said embossing runs in a straight line over the entire surface of the board from one end to the other. If, for example, the board has a rectangular shape, then the embossing or, if there is more than one embossing, the embossings extend from, for example, the short side of the board to the opposite short side parallel to the long sides of the board.

The embossed area is created during the step of compressing the board of the base material and the layer of laminating material before cutting the board, as required by the present invention. The compression step, as part of the manufacturing process for manufacturing the panel, is described in more detail below. Accordingly, due to compression, at least the base material board or both the base material board and the layer

- 2 041190 laminating material have a greater density in at least one area of compression, compared with the remaining areas. Due to the higher density, these areas have increased mechanical strength. These higher strength compression regions form the subsequent edges of the locking panels when they are milled from the boards. Accordingly, the present invention makes it possible in one step to form embossings on the board at a point where, for example, a beveled edge would later be present on a panel. Due to the compression (and the resulting higher density of the board/panel compression areas), not only does the mechanical strength of both the formed panel edge and the mechanical locking means increase, but the present invention simultaneously eliminates an additional work step (in which the embossing has to be milled separately). or chamfer).

The width of the transitions is the width of the area where the top surface of the platen transitions into the bottom surface, ie the embossed surface.

The width of a mechanical lock is the width of said lock, measured from the top edge of the panel to the outer edge of the respective lock. Optionally, additional sacrificial processing width is also added to the width of the embossed area.

According to the invention, a manufacturing tolerance is added to the total embossing width, which depends on the width of the cut. The specified manufacturing tolerance is calculated as 0.10-3.0 times the width of the cut.

Thus, the present invention specifically defines the overall width of the embossing, which ensures that, even with systematic or random errors that occur during board cutting, which, for example, can lead to a parallel displacement of the board during cutting or a slightly diagonal cut of the board, optimal results are achieved when plate has already been cut. Even if these cutting errors occur during cutting, the edges of the resulting panels are still perfectly aligned with each other, so that when said panels are aligned with, for example, a floor covering, errors at the edge junction do not occur. The present invention ensures that the edges of the produced panels are always of the same height and that there is no mismatch between the panels.

According to a preferred embodiment, the manufacturing tolerance is calculated as 0.25 to 2.5 times the width of the cut, preferably 0.40 to 2.0 times the width of the cut, more preferably 0.50 to 1.75 times the width of the cut, particularly preferably 0.60 to 1.60 times the width of the incision.

Preferably, the rectilinear cutting of the board is carried out by sawing, in particular with a circular saw.

The embossed area may be completely embossed, i. e. wherever there is an embossed area on the board, only one embossing remains in the cross section.

However, according to a specific embodiment, said at least one embossed area comprises two embossings extending in pairs and parallel, said embossings extending in a straight line (i.e. they have a straight path) and over the entire surface of the board.

If, for example, there are two embossments to form an embossed area, it is preferable that the embossings have a width and the distance between both embossings satisfies the following criteria: 0.5 y < z < 10.0 y, preferably 1.0 y < z < 5, 0 y, particularly preferably 1.5 y < z < 3.2 y, where y is the width of the embossing and z is the distance between two embossings. The embossing width is the distance at which said embossing is embossed into the surface of the board. The width is measured transverse to the embossing direction.

Optionally, the embossings have a width of 1.0 to 20 mm, preferably 3.0 to 5.0 mm.

In addition, the distance between the two embossings forming each pair of embossings may be 1.5 to 50 mm, preferably 5.0 to 25 mm, particularly preferably 7.5 to 15 mm.

Preferably in any of the above cases, the board is rectangular in shape with at least one embossed area, for example the embossings run parallel to the edges of the board.

In addition, the plate preferably contains more than one embossed area, for example, at least two embossed areas. Said several embossed areas may, for example, run parallel to each other; alternatively or additionally, it is also possible that the embossed regions intersect at right angles. If the board is rectangular, then said embossed areas, for example, run parallel to each edge of the board. That is, the board preferably has a rectangular shape with long sides and short sides, has at least one embossed area that intersects each other and runs parallel to the long sides and at least one embossed area that runs parallel to the short sides.

Even more preferably, the number of embossed areas parallel to the long sides is greater than the number of embossed areas parallel to the short sides.

For example, the board may comprise 2 to 15, preferably 5 to 12, particularly preferably 8 to 11, such as 9 embossed areas parallel to the long sides and/or 1 to 6, preferably 1 to 5, particularly preferably 2 up to 4, for example 3 embossed areas parallel to the short sides.

In the exemplary case, the board is rectangular and has 9 equally spaced embossed areas parallel to the long edges of the board, and 3 equally spaced embossed areas parallel to the short edges of the board.

The embossing depth of said at least one embossed area, such as said at least one embossed area, such as embossing, measured from the surface of the board, is preferably 0.1 to 2.0 mm, preferably 0.3 to 1.0 mm, particularly preferably 0.5 to 0.7 mm.

The geometry of the transitions is preferably rectilinear or curvilinear when viewed in a cross section of the plate in the direction of execution of said at least one embossing. In the case where the transitions are curvilinear, a concave geometry or a geometry transitioning from the board surface to the bottom of the embossing in a convex/concave manner is particularly preferred.

A particularly preferred width of each transition in relation to the total width of the embossed area may be 0.1% to 20%, preferably 1% to 10%, particularly preferably 2.5 to 5%.

With regard to the width of the transitions, the width of each transition is preferably 0.2 to 10.0 mm, preferably 0.5 to 5.0 mm, particularly preferably 0.7 to 1.5 mm.

The paired mechanical locking means, which are provided on both ends of the obtained panels, usually have different widths.

For example, the first width of the first mechanical closing means is 2.0 to 20 mm, preferably 5.0 to 15 mm, particularly preferably 7.0 to 9.0 mm.

Additionally or alternatively, the second width of the second mechanical closing means is 0 to 10 mm, preferably 0.5 to 5 mm, particularly preferably 1.0 to 2.0 mm.

The optional width of the sacrificial treatment may be from 0 to 10 mm, preferably from 1.0 to 8.0 mm, particularly preferably from 2.0 to 6.0 mm.

In cross section, said at least one embossed area, or, when the embossed area is formed by more than one embossing, said at least one embossed area or said embossings have a U-shaped, semicircular, trapezoidal, rectangular, trough-like shape, and combinations thereof.

In particular, if the embossed area is formed by only one embossing, a U-shaped cross section is preferred. In this context, furthermore preferably, the bottom surface of the U-embossing has a part that runs parallel to the top surface of the board. If the embossed area is formed by more than one embossing, preferably each embossing has a portion that extends parallel to the top surface of the board. If, for example, the embossed area is formed by two embossings, it is also possible that, for example, the outer embossing transitions have, for example, a concave cross-section, while the inner embossing transitions have a different shape. The above embodiment is an example of a combination of different cross-section geometries, which is particularly possible when more than one embossing forms an embossed area.

The surface of the board, which is the area where the board does not have these embossings, is preferably smooth or has embossings such as, for example, wood, tile or stone imitation. The embossings can contribute to the imitation and feel of the surface, respectively, of natural wood, texture or stone.

According to a preferred embodiment, in the embossed area, for example in the embossed areas, the transition and/or bottom surface is smooth and/or the layer of laminating material in the transition and/or bottom area is one-color.

For example, the base material of the board of the base material may be selected from the group consisting of Medium Density Fibreboard (MDF), High Density Fibreboard (HDF), Direct Pressure Laminate (LPD), Continuous Pressure Laminate (CLD), particle boards , oriented strand boards, mineral wool boards, cement fiber boards, PVC thermoplastics, foams and combinations thereof.

The layer of laminating material forming the surface of the board preferably comprises at least one decorative layer and at least one wear layer. The wear layer may also be the top layer. However, it is also possible that more layers than the aforementioned specific layers are present.

In particular, the decorative layer comprises a wood-like decor which is identical to the wood-fiber surface embossings of the board, said decorative layer extending in such a way that the wood-like decor corresponds to the wood-fiber surface embossings of the board.

For example, a layer of laminating material is applied to a base material board using

- 4 041190 thermosetting resin.

In the method according to the invention, it is particularly preferred if the board comprises two embossings running in pairs and parallel in said at least one embossed area. In this case, it is possible that the embossings running in pairs and in parallel are separated by a projection, the embossings on said projection having inner sides. This allows said at least one of the inner sides to be monitored by a detection means, such as an optical detection means (for example, a camera), which provides a control signal that is used to control the position of the cutting means during cutting.

In this case, the inner sides are made in one color, especially in a light color, such as white or shades of white, which simplifies and increases the accuracy of control.

According to a second embodiment, the present invention relates to a pressure plate that can be used in the manufacture of the plates described above. In accordance with the invention, the pressure plate comprises a main body containing a pressure surface for compressing the plate, said main body comprising:

at least one pressing area having at least one embossing means that protrudes beyond the pressing surface, wherein said at least one embossing means extends rectilinearly and over the entire pressing surface, while in a cross section perpendicular to the direction of passage of each specified at least one means for performing embossing, said pressure area has transitions in each outermost section of the pressure area, where the transition of the pressure surface to the upper surface of the pressure area occurs, and these transitions have a width and are adjacent to a part of the pressure area in which the top surface is parallel to the pressing surface.

Said at least one pressing area is intended to carry out the method described above, i. e. preferably has an overall width which is the sum of the width of the transitions, the width of the cut when the board is cut with a cutter having the specified cut width, the first width and the second width of the paired mechanical locking means to be milled at opposite edges of the raw boards, the width of the sacrificial treatment , as well as production tolerance, and the specified production tolerance is calculated as 0.10 - 3.0 - multiple of the cut width.

The dimensions of the pressure areas of the pressure plate correspond to the dimensions of the embossed areas of panels made with the pressure plate made in accordance with the present invention.

In a preferred embodiment, the manufacturing tolerance is calculated as 0.25-2.5 times the width of the cut, preferably as 0.40-2.0 times the width of the cut, more preferably as 0.50-1.5 times the width of the cut, particularly preferably as 0.60-1.60 times the width of the cut.

Moreover, preferably, said at least one pressing area comprises two embossing means extending in pairs and parallel, said embossing means extending in a straight line and over the entire pressing surface of the pressure plate.

In particular, the embossing means have a width with a distance between the two embossing means that satisfies the following criteria: 0.5 y' < z' < 10.0 y', preferably 1.0 y' < z' < 5.0 y', particularly preferably 1.5 y' < z' < 3.2 y'.

For example, the embossing means have a width of 1.0 to 20 mm, preferably 3.0 to 5.0 mm.

Preferably, the distance between the two embossing means forming each pair of embossings is 1.5 to 50 mm, preferably 5.0 to 25 mm, particularly preferably 7.5 to 15 mm.

In particular, the pressure plate has a rectangular shape and said at least one pressure region, for example the embossing means, extends parallel to the edges of the pressure plate.

Further preferably, the pressure plate comprises at least two pressure regions which run parallel to each other or intersect at right angles.

In a particular embodiment, the pressure plate has a rectangular shape with long sides and short sides and includes at least one pressure area parallel to the long sides and at least one pressure area parallel to the short sides intersecting each other.

Preferably, the number of pressure areas parallel to the long sides is greater than the number of pressure areas parallel to the short sides.

For example, the pressure plate may comprise 2 to 15, preferably 5 to 12, particularly preferably 8 to 11, such as 9 pressure areas parallel to the long sides and/or from

- 5 041190 to 6, preferably 1 to 5, particularly preferably 2 to 4, for example 3 pressure areas parallel to the short sides.

The height of said at least one pressing area, for example the embossing means, is preferably 0.1 to 2.0 mm, preferably 0.3 to 1.0 mm, particularly preferably 0.5 to 0.7 mm.

The pressure plate transitions can be straight or curved. As regards the straightness or curvature of the transition, they correspond to the transition sections of the slab mentioned above, having the corresponding geometry. In particular, if the transitions of the pressure plate are curved, said curved transitions are convex, corresponding to the concave transitions of the plate. Accordingly, a concave/convex geometry is also possible, allowing a corresponding convex/concave transition in the slab to be obtained.

According to a specific embodiment, the width of each transition in relation to the total width of the pressing area is 0.1 to 20%, preferably 1 to 10%, particularly preferably 2.5 to 5%.

Preferably the width of each transition is 0.2 to 10.0 mm, preferably 0.5 to 5.0 mm, particularly preferably 0.7 to 1.5 mm.

In yet another embodiment, the cross section of said at least one pressure region, such as the embossing means, may be U-shaped, semi-circular, trapezoidal, rectangular, trough-shaped, and combinations thereof.

The pressure surface of the pressure plate, that is, the surface of the pressure plate, excluding the pressure areas, is preferably smooth or embossed, such as imitation wood, tile or stone fibers. The pressing surface of the pressing plate can suitably perform embossing of, for example, a wood-like structure and a board in pressing.

Furthermore, preferably, the surface of the pressure plate in the region of transitions and/or the top surface is smooth.

According to a third aspect of the present invention, a method for manufacturing a board suitable for making panels is described, said method comprising using a base material board, applying a layer of laminating material to the surface of the base material board, bonding the laminating material layer and the base material board by pressing with using a pressure plate made according to the present invention as described above, wherein the pressing surface of the pressure plate is pressed into a layer of laminating material, or pressing a base material board laminated with a layer of laminating material using a pressing plate made according to the present invention , as described above, wherein the pressure surface of the pressure plate is pressed into the layer of laminating material, wherein said at least one pressing region of the pressure plate compresses the layer of laminating material and/or the slab of base material to form of at least one embossed area in the layer of laminating material and/or in the base material board, said at least one embossed area preferably has an overall width which is the sum of the cut width, the width of the first profile, the width of the second profile, the width of the transitions, the width of the sacrificial processing, as well as manufacturing tolerance, and the specified manufacturing tolerance is calculated as 0.10-3.0 times the width of the cut.

With regard to the pressure plate, all the details associated with the second aspect of the present invention are equally included for carrying out the plate manufacturing method.

According to a preferred embodiment, the core material of the board is selected from the group consisting of medium density fibreboard (MDF), high density fibreboard (HDF), direct pressure laminate (LPD), continuous pressure laminate (LDL), wood - particle boards, oriented strand boards, mineral wool boards, cement fiber boards, PVC thermoplastics, foams and their combinations.

In yet another aspect of the present invention, the layer of laminating material comprises at least one decorative layer, at least one wear layer, and at least one top layer.

Furthermore, preferably the decorative layer comprises a wood-like decor which is identical to the embossings of the pressing surface of the pressure plate, said decorative layer being designed such that the decor corresponds to the embossings of the pressing surface.

In accordance with one aspect of the present invention, a layer of laminating material is impregnated with a thermosetting resin before, during and/or after application to the surface of the base material board.

According to another preferred embodiment of the present invention, the protective layer is applied to the surface of the base material board opposite to that

- 6 041190 on which a layer of laminating material is applied.

The surface of the base material plate on which the laminating material layer is applied may be smooth or may have embossings corresponding to the press plate embossing means.

In addition, the present invention relates to a board for the manufacture of panels, containing a board of a base material, laminated on the surface of the board with a layer of laminating material, forming a laminated surface of the board, and said board has at least one embossed area containing at least one embossing of the laminated surface , which runs in a straight line and over the entire surface of the plate, while in a cross section perpendicular to the direction of passage of each specified at least one embossing, the specified embossed area has transitions in each most remote section of the embossed area, where the transition of the surface to the bottom of the embossed area occurs, with wherein said transitions have a width and a part of the embossed area adjoins them, and the bottom of the embossed area is parallel to the surface of the plate, while preferably, said at least one embossed area has a total width, which is preferably the sum of the width of the cut when the plate is cut by a cutting tool having the specified cut width, the first width and the second width of the paired mechanical locking means, which must be milled at opposite edges of the raw boards, the width of the sacrificial treatment, as well as the manufacturing tolerance, and the specified manufacturing tolerance is calculated as 0.10-3, 0 times the width of the cut.

All aspects related to the above plate described with the previous aspects of the present invention are also valid for the plate made in accordance with the present invention. For example, the board can be manufactured according to the above-mentioned board manufacturing method according to the present invention.

In addition, the present invention relates to a panel comprising a board of base material laminated on the surface with a layer of laminating material, forming a laminated surface of the panel, combining mechanical locking means in pairs at opposite edges of the panels containing the first mechanical locking means having a first width at the first edge , and a pair of second mechanical locking means having a second width at the opposite edge, while along each opposite edge there is an embossment of the laminated surface, each embossing being part of the corresponding edge, extending rectilinearly and over the entire surface of the plate, moreover, in a transverse direction perpendicular to the direction of passage each embossing, has a transition in the area farthest from the corresponding edge, where there is a corresponding embossing, where the transition of the surface to the bottom of the embossing occurs, and these transitions have a width and a part of the embossed area adjoins them sti where the bottom of the embossed area is parallel to the board surface.

Paired locking means pairs two identical panels along opposite edges where there are paired locking means. This coupling mechanism is otherwise well known in the art.

All aspects related to the above panel described with the previous aspects of the present invention are also valid for the panel made in accordance with the present invention. For example, the panel may be manufactured in accordance with the first aspect of the present invention.

Preferred embodiments of the invention are described below with reference to the drawings, which are intended to illustrate proposed preferred embodiments of the invention and not to limit them.

Brief description of the drawings

Fig. 1 is a schematic side view of two connected prior art panels and their connection.

Fig. 2 is a schematic side view of two prior art connected panels with swollen edges.

Fig. 3 is a schematic side view of a V-bevel known in the art.

Fig. 4 shows a schematic side view of the joint area of two V-beveled panels, together with an optimal and incorrectly running joint line.

Fig. 5 is a cross-sectional view of a pressure plate according to the invention used in the production of a plate.

Fig. 6 is a schematic view of an inverted pressure plate with pairs of longitudinal and transverse groove embossing means.

Fig. 7 shows the slab before panel sawing and milling, together with the surface of a pressure plate made in accordance with the invention.

Fig. 8 shows the slab before panel sawing and milling, together with the surface of a pressure plate made in accordance with the invention.

- 7 041190

Fig. 9 shows a schematic side view of the area of abutment of two panels made in accordance with the invention, together with an optimal and offset line of abutment.

Fig. 10 schematically illustrates how the optimal support and cut line is determined by means of optical distance measurement along the unfinished side surface.

In FIG. 11 shows two panels cut from a slab with specific dimensions.

Fig. 12a shows a schematic side view of two joined panels with a symmetrical U-bevel.

Fig. 12b is a schematic side view of two joined panels with an asymmetrical U-bevel.

Fig. 12c shows another schematic side view of two connected panels with an asymmetrical U-bevel.

Description of Preferred Embodiments

In the drawings, the same reference numbers refer to the same elements, even if they are not explicitly mentioned in the description of the corresponding drawing.

Fig. 1 shows a schematic side view of two connected prior art panels 1, 1' connected along an abutment line 6 and their connection. Classic medium to high density (MDF/HDF) floor sandwich panels are known in the art and are usually made from a base material 4 of (MDF/HDF), a decorative layer 2 usually consisting of impregnated paper and a (generally transparent) wear and tear or wear layer 3, plus a backing 5 which can be made of tracing paper or soundproofing, etc., having a front or visible surface S. They also in most cases contain some variants of the locking means L1, L2, such as locking profiles, usually on all four sides of sandwich panels, long and short.

Fig. 2 shows a schematic side view of two connected prior art panels 1, 1' as described in FIG. 1 with some degree of swelling in the vicinity of a simple butt joint 6. Such swelling on adjacent surfaces of the panels can occur when moisture or cleaning fluids enter the MDF/HDF backing material 4 or by simple thermal expansion of any material such as MDF or PVC. A similar situation also arises when two adjacent panels 1, 1' are not located exactly in the same horizontal plane, with one adjacent edge slightly higher than the other, which can be caused, for example, by an uneven underlying surface. Another reason for this problem may be small deviations in panel thickness caused by uncontrolled manufacturing parameters. Once such swelling or horizontal displacement occurs at the edges of the panel, the protective layer 3 can be easily affected by everyday wear and tear, and it can happen that the decorative layer wears off, resulting in unaesthetic floor coverings.

Fig. 3 is a schematic side view of two prior art joined V-beveled panels. Such chamfers between adjacent panels are used both for the technical reasons mentioned above, and because the chamfers provide an aesthetic appearance to the installed floor panels by contrasting the appearance of the chamfer or color with the decor, and also because small irregularities in the underlying surface are less noticeable and and thus less annoying. Such V-shaped and decorated chamfers are known in the art.

Fig. 4 shows a schematic side view of the area of contact between the two panels 1, 1', as described above with respect to FIG. 3 with a V-shaped bevel and with an optimally aligned fit line 6 and an offset fit line 6'. It is obvious that even a slight displacement of the cut (and, consequently, of the subsequently milled profiles) in the manufacture of panels by sawing them from a plate (not shown) relative to the depressed chamfers (i.e. V-shaped chamfer) is very visible on the V-shaped chamfer profile , since any displacement of the cut will also lead to a misalignment of the height of the supporting surface. Such a shift in the height of the bearing surface will also result in cracks or cuts, which can accumulate liquids and promote swelling.

Fig. 5 shows a pressure plate 11 made in accordance with the present invention. The pressure plate comprises a main body 11' as well as a pressure surface 11 on which, in the case of the pressure plate 11 shown in FIG. 5, pressing area II is aligned. The pressing region II comprises a pair of embossing means 20 which protrude beyond the smooth pressing surface 11 of the pressing plate 11. The embossing means 20 extend rectilinearly over the entire surface of the pressing plate 11, i. in the case shown in FIG. 5 move into the plane of the drawing. In alternative embodiments, the pressure plate 11 can also comprise more than one pressure region II extending parallel to each other or intersecting, for example, at right angles (see, for example, FIG. 6). It is also possible that the pressure area II contains only one embossing means. The embossing means 20 protrude from the pressing surface 11 by a height h'. In the cross section shown, the pressing area II has an overall width W'. Accordingly, the pressing surface 11 has two transitions T1', T2', where the pressing surface 11 passes from the protruding embossing means 20, in particular to

- 8 041190 upper surface B' means 20 for embossing. Said transitions T1', T2' are located on the outermost portion of the pressure region (II). As can be seen from FIG. 5 in cross section, the transitions T1', T2' are convex and have the same width t1', t2'. However, transitions can also be linear. The top surface B' of the pressing area II or the embossing means 20 respectively extends parallel to the pressing surface 11'. Since the pressure plate 11 has two different embossing means 20, these means are separated from each other by a gap in which the top surface is offset from the top surface B'. Said gap has a width z, while the embossing means 20 themselves have a width y'. The total width W' of the pressing area is respectively the sum of the width y' of the means 20 and the width z of the gap separating the means 20. This width W', on the other hand, is calculated for the manufacture of boards from which panels can be sawn. The indicated width W' is well adjusted in order to avoid panels with mismatched edges when sawing the boards.

Fig. 6 is a schematic illustrative view of an inverted pressure plate according to the invention with the pairs of longitudinal and transverse embossing means detailed in FIG. 5. Both embossing means 20 and 21 may have identical dimensions except for their direction.

Fig. 7 shows a plate 10 made with a pressure plate 11, as shown in detail in FIG. 5 and 6 before sawing into raw panels and milling to form the final panels. Also shown is a pressure plate 11 according to the invention. The board as a whole has the same sandwich structure as the panels shown in FIG. 1, i.e. has a base material 4 covered, for example, with a decorative layer 2 and a wear layer 3 (position numbers of the base material, the decorative layer and the wear layer are not shown for clarity). The base material can be laminated with a decorative layer and a wear layer while pressing the platen 10 with the pressure plate 11. As shown in FIG. 7, when the board is pressed with the pressure plate 11, an embossed area I is formed, which contains two embossings 9 with a width y. Said embossed region I corresponds to the pressing region II of the pressure plate 11. Said two embossments 9 are separated by a projection corresponding to the gap of the corresponding pressure plate 11. Said projection comprises inner side surfaces 18. In FIG. 7 also shows the cutting section 14 and the milling section 13 in which the board is cut in later steps and in which the locking elements will be formed (already shown in the board 10 shown in FIG. 7). The locking elements shown in Fig. 7 are shown for dimensional purposes only, since at this stage the laminated board has not yet been sawn and the locking elements have not yet been milled. It is not necessary to form embossings over the cut sections 14 and milling sections 13 of the profile, since they will be removed anyway. Although a pair of V-embossings can be applied with the pressure plate, the U-embossings shown in FIG. 7. After the embossed area I containing the embossings 9 is made on the board 10 by the pressure plate 11, the sandwich board 10 is sawn into a panel (not shown). For this, saws with a very high sawing speed (of the order of several meters per second) are used. Obviously, such high sawing speeds require a compromise with accuracy.

By analogy with FIG. 7 FIG. 8 shows the board 10 before panel sawing and milling, together with the surface of the corresponding pressure plate 11 used to make it. Unlike the embodiment shown in FIG. 7, the embossed area I has only one embossing that extends across the entire width of the embossed area. At the same time, the respective pressure plate 11 has a pressure region II which has only one embossing means.

Fig. 9 is a perspective view of the plate 10 shown in FIG. 8 after the pressing step. A cutting step is shown in which the board 10 is cut, for example with a circular saw, into two separate raw panels 1 and 1'. Position number 15 indicates the ideal cutting line. However, if there are any alignment errors in either the panel 10 or the cutting means, such as a circular saw, then cutting occurs, for example, along a misdirected (deviating) cutting line 16. Errors can be of a systematic origin (for example, if the circular saw is slightly misaligned) or random in nature (for example, a one-time misalignment of the plate 10 during cutting). This irregular line 16 may, for example, run parallel to the ideal cutting line 15 (eg parallel offset) and/or at a slight angle to it (as in the case shown in FIG. 9). By specifically defining the width of the pressing area in the pressing plate 11 or in the corresponding embossed area on the plate, it is ensured in the present invention that the aforementioned errors occurring during the cutting step can be compensated. Because the U-shaped embossing shown in FIG. 8 and 9 is for the most part a nearly horizontal surface, a slight shift in the cutting line does not lead to any shift in the height of the adjacent surface of the manufactured panels 1, 1'. The misalignment is much less visible to the human eye, and no cracks are created to collect fluid. In addition, portions of the spilled liquid remain on the substantially nearly horizontal portions of the surface of the U-grooves and may be removed or may evaporate on their own, while

- 9 041190 much more liquid will reach the thrust surfaces of the V-grooves and may cause swelling. Correspondingly, also the boards 1, 1' obtained by cutting along an incorrectly running cutting line have a shape perfectly matched to each other, so that fewer defective boards result.

The decorative layer may also contain special parts for decorating the bevel, for example, a color contrasting with the surface of the panel can be used for the bevel. This is usually a darker color than the surface decor of the panel.

Fig. 10 illustrates the step of cutting a slab 10 made in accordance with FIG. 7 containing an embossed area I with two embossings 9. Since the inner sides 18 of each projection between the two embossings 9 are in any case sawn and milled at a later stage, it is possible to print a temporary marker on at least one of these inner sides 18, for example , by applying a uniform color or decorative layer. This marker can then be used in conjunction with optical distance sensors 19 to align high-speed saws in real time, thereby providing greater precision in the sawing process. The marker may have a specific, detectable color, or may simply be missing a decorative piece. In FIG. 10 schematically shows how the optical distance measuring means 19 determines the optimal abutment line 15 and cut along the lateral side 18 without finishing.

Fig. 11 shows two panels 1, 1' after the raw panels cut from the board have been milled to obtain the locking means L1, L2. In FIG. 11, the slabs 1, 1' are artificially aligned as they would be in a (no longer existing) slab 10, as shown in FIG. 7 or 8. FIG. 11 shows the selection, respectively, of the width W of the embossed area I in the plate 10 or the width W' of the pressure area II in the pressure plate 11.

Said at least one embossed area I has a total width W, which is the sum of the width d of the cut, the first width l1 of the first mechanical lock L1 (measured from the abutment line of the upper edge of the corresponding panel 1), the second width 12 of the second mechanical lock L2 (measured from the abutment line of the upper edge of the corresponding panel 1'), the width t1, t2 of the transitions T1, T2, the width m1 + m2 of the sacrificial treatment, as well as the manufacturing tolerance x (which is the sum of the depicted parts xi and xii of the manufacturing tolerance x), and the specified manufacturing tolerance x is calculated as 0.10-3.0 times the width (d) of the incision.

The corresponding pressure plate respectively has a pressure region II with a total width W', which is the sum of the widths t1, t2 of the transitions T1, T2 of the embossed region I of the plate 10, the width d of the cut when the plate 10 is cut by means of a cutting means having said width d of the cut, the first width l1 and the second width l2 of the paired mechanical locking means L1, L2, which are to be milled on opposite edges of the raw slabs, the width m1 + m2 of the sacrificial treatment, as well as the manufacturing tolerance x, the specified manufacturing tolerance x being calculated as 0.10 - 3.0 is a multiple of the width d of the cut.

The manufacturing tolerance x gives some degree of play so that when the board is not perfectly cut, usable panels 1, 1' can still be produced.

Fig. 12a-c are schematic side views of two connected panels 1, 1' made in accordance with the present invention. To obtain such finished panels from raw panels sawn from board 10, it is necessary to cut a large laminated board into panels and mill the locking elements L1, L2 (generally in the form of locking profiles) at the edges of the cut raw panels. Even if the aforementioned cutting line does not completely pass through the ideal cutting line, the aforementioned play, i.e. additional manufacturing tolerance x, ensures that the finished panels 1,1' always abut each other at the same height. An example of two perfectly cut and milled panels 1, 1' is shown in FIG. 12a. In FIG. 12b and 12c (numbers not shown) are cross sections of imperfectly cut and milled panels 1, 1' in installed form. As can be seen, even if the cut and, accordingly, the line of abutment, is not in the very middle of the chamfer obtained (for example, if there has been a complete parallel displacement of the abutment line), it is possible to perfectly match the panels 1, 1', without the errors inherent in the prior art, for example , those discussed above with reference to FIG. 4.

Item number list , 1' - Panel

- Decorative layer

- wear layer

- Panel base material

- Substrate

- Optimal butt joint ' - Mismatched butt joint

L 1, L2 - Locking means or elements

-

Claims (16)

11 - Width of locking element L1 12 - Width of locking element L2 I - Embossed area W - Total width of the embossed area 8 - Bottom of the embossed area 9 - Embossing Y - Embossing width Z - Distance between embossings h - Depth of embossings T1, T2 - Emboss transitions 9 t1, t2 - Transition width T1, T2 10 - Slab before sawing and milling on the panel S - Slab surface 10 11 - Pressure plate 11' - The main part of the pressure plate 11 - Pressing surface of the pressure plate II - Pressure area W' - Total width of the pressure area B' - Pressure area surface 20, 21 - Embossing means y' - Width of embossing means z' - Distance between embossing means h' - Height of embossing means T1', T2' - Transitions of means 20, 21 for performing embossing t1', t2' - Width of transitions T1', T2' 13 , 13' - Profile milling section 14 - Cutting area d - Cutting width m1, m2 - Sacrificial width x - Manufacturing tolerance 15 - Optimum cutting line 16 - Offset cutting line 17 , 17' - Decorative inner side chamfer 18 - Embossed inner side 19 - Optical distance sensor CLAIM 1. A method for manufacturing panels (1, 1') from a plate (10), including the use of a plate (10) containing a plate (4) of a base material laminated on the surface with a layer (2, 3) of a laminating material to form a laminated surface (S ) of a plate (10), wherein said plate (10) has at least one embossed area (I) containing at least one embossing (9) of the laminated (2, 3) surface (S), which runs straight across the entire surface ( S) plate (10), and in the transverse direction, perpendicular to the direction of passage of each specified at least one embossing (9), the specified embossed area (I) has transitions (T1, T2) in each outermost section of the embossed area (I), where there is a transition from said surface (S) to the bottom (B) of the embossed area (I), wherein said transitions (T1, T2) have a width (t1, t2) and are adjacent to a part of the embossed area (I) in which the bottom (B) embossed area (I) parallel to the surface (S) plate (10), straight linear cutting of the plate (10) along the cutting line passing in each of the specified at least one embossed area (I), using a cutting tool having a width (d) of the cut, in one or more cutting steps to produce raw boards, milling on opposite edges of raw plates of paired mechanical locking means (L1, L2) containing a first mechanical locking means (L1) having a first width (11) and a paired second mechanical locking means (L2) having a second width (12), characterized in that said at least one embossed area (I) has a total width (W), which is the sum of the width (d) of the cut, the first width (11) of the first mechanical lock (L1), the second width (12) of the second mechanical lock (L2 ), width (t1, t2) of transitions (T1, T2), width (m1+m2) of sacrificial processing and manufacturing tolerance (x), and the specified manufacturing tolerance (x) is calculated as 0.10-3.0-kra t width (d) of the cut. 2. The method according to claim 1, characterized in that the manufacturing tolerance (x) is calculated as 0.25-2.5 times the width (d) of the cut, preferably 0.40-2.0 times the width (d) of the cut, more preferably - 0.50-1.75 times the width (d) of the slit, particularly preferably 0.60-1.60 times the width (d) of the slit. 3. Method according to claim 1 or 2, characterized in that the rectilinear cutting of the plate (10) is carried out by sawing, in particular with a circular saw. 4. A method according to one of the preceding claims, characterized in that said at least one embossed area (I) comprises two embossings (9) running in pairs and parallel, which run rectilinearly over the entire surface (S) of the plate (10). 5. Method according to claim 4, characterized in that the embossings (9) have a width (y) and the distance (z) between both embossings (9) satisfies the following criteria: 0.5 y < z < 10.0 y, preferably 1 .0 y < z < 5.0 y, particularly preferably 1.5 y < z < 3.2 y, and/or the embossings (9, 9') have a width (y) from 1.0 to 20 mm, preferably from 3.0 to 5.0 mm and/or the distance (z) between both embossings (9) forming each pair of embossings (9) is 1.5 to 50 mm, preferably 5.0 to 25 mm, especially preferably 7.5 to 15 mm. 6. Method according to one of the preceding claims, characterized in that the plate (10) has a rectangular shape and at least one embossed area (I), for example the embossings (9) run parallel to the edges of the plate (10), or the plate (10) contains at least two embossed areas (I) that run parallel to each other and/or intersect at right angles. 7. The method according to one of the preceding claims, characterized in that the plate (10) has a rectangular shape with long sides and short sides and contains at least one embossed area (I) intersecting with each other, parallel to the long sides, and at least one embossed area (I) parallel to the short sides, preferably more embossed areas (I) parallel to the long sides than the number of embossed areas (I) parallel to the short sides. 8. Method according to claim 7, characterized in that the board (10) comprises 2 to 15, preferably 5 to 12, particularly preferably 8 to 11, for example 9 embossed areas (I) parallel to the long sides and/or 1 to 6, preferably 1 to 5, particularly preferably 2 to 4, for example 3 embossed areas (I) parallel to the short sides. 9. Method according to one of the preceding claims, characterized in that the depth (h) of said at least one embossed area (I), for example embossings (9), is from 0.1 to 2.0 mm, preferably from 0.3 up to 1.0 mm, particularly preferably from 0.5 to 0.7 mm. 10. Method according to one of the preceding claims, characterized in that the transitions (T1, T2) are straight or curved. 11. The method according to one of the preceding claims, characterized in that the width (t1, t2) of each transition (T1, T2) in relation to the total width of the embossed area (I) is from 0.1 to 20%, preferably from 1 to 10 %, particularly preferably from 2.5 to 5%, and/or the width (t1, t2) of each transition (T1, T2) is from 0.2 to 10.0 mm, preferably from 0.5 to 5.0 mm, particularly preferably 0.7 to 1.5 mm. 12. Method according to one of the preceding claims, characterized in that the first width (l1) of the first mechanical locking means (L1) is 2.0 to 20 mm, preferably 5.0 to 15 mm, particularly preferably 7.0 to 9.0 mm and/or the second width (l2) of the second mechanical locking means (L2) is 0 to 10 mm, preferably 0.5 to 5 mm, particularly preferably 1.0 to 2.0 mm. 13. Method according to one of the preceding claims, characterized in that the width (m1 + m2) of the sacrificial treatment is 0 to 10 mm, preferably 1.0 to 8.0 mm, particularly preferably 2.0 to 6.0 mm . 14. A method according to one of the preceding claims, characterized in that said at least one embossed area (I) or embossments (9) in cross section are U-shaped, semi-circular, trapezoidal, rectangular, trough-shaped and combinations thereof, and/ or the surface (S) of the board (10) is smooth or embossed, such as imitation of wood, tile or stone fibres, and/or the surface of the transitions (T1, T2) and/or the bottom (B) is smooth and/or the layer (2 , 3) the laminate material in the transition area (T1, T2) and/or the bottom (B) is one color. 15. The method according to one of claims 4 to 14, characterized in that the pairwise and parallel embossings (9) are separated by a protrusion on which the inner sides (18) of the embossings (9) are located, while said at least one of the inner the sides are monitored by a detection means (19), such as an optical detection means, which provides a control signal that is used to control the position of the cutting means during the execution of the cutting. 16. Method according to claim 15, characterized in that said inner sides (18) are made in one color. -