WO2024127169A1

WO2024127169A1 - Panel and method for designing and manufacturing such a panel

Info

Publication number: WO2024127169A1
Application number: PCT/IB2023/062310
Authority: WO
Inventors: Matthias CLAERHOUT; Julien Brunet
Original assignee: Unilin, Bv
Priority date: 2022-12-15
Filing date: 2023-12-06
Publication date: 2024-06-20

Abstract

A panel (10) for forming a covering is provided having a first pair of opposite edges (14, 15) and a second pair of opposite edges (56, 57). The first pair of opposite edges (14, 15) and the second pair of opposite edges (56, 57) include coupling parts, a profile of at least one of the coupling parts of the first pair of opposite edges (14, 15) provided with a cut- out (22, 35) such that left-over pieces (30, 31) are prevented or removed at corners of the panel (10). A method is provided for designing a panel (10) where left-over pieces are prevented or removed at the corners. A method for manufacturing a panel (10) is provided where left-over pieces are prevented or removed at the corners by adding a cut-out (22, 35) to a profile of at least one coupling part of a first pair of opposite edges (14, 15) or by vertical movement of a milling tool.

Description

PANEL AND METHOD FOR DESIGNING AND MANUFACTURING SUCH A PANEL

[01] TECHNICAL FIELD

[02] The disclosure generally relates to a panel, a method for manufacturing such a panel, and a method for designing such a panel.

[03] More particularly, the disclosure relates to a panel with a first pair of opposite edges and a second pair of opposite edges. The panel comprises a coupling part on one of the edges, which makes it possible to couple the panel to another similar panel; the coupling part is further adapted to prevent or remove a left-over piece.

[04] BACKGROUND

[05] Such panels are known, for example, from WO 97/47843. In this case, a rectangular floor panel is provided with long and short edges. A coupling part at one of the long edges is configured to cooperate with the coupling part at the other long edge of another similar panel. A coupling part at one of the short edges is configured to cooperate with the coupling part at the other short edge of another similar panel. It is known that such coupling parts can be formed using a classical tongue and groove connection, wherein these, when installing the floor panels, possibly are glued into each other or using mechanical coupling parts providing for a mutual locking of the floor panels in horizontal as well as in vertical directions. The cooperation between the tongue and the groove produces vertical interlocking. The horizontal interlocking results from an interlocking lip engaging with a downwardly directed interlocking groove.

[06] WO 97/47834 describes how the respective coupling parts at two opposite sides can be formed in a continuous machine, in other words, while moving the panel over rotating mechanical cutting tools. This method is also called “continuous milling.” In the case that a profile is to be applied on all four sides, the panel may be displaced using two perpendicular movements, whereby during the first movement, profiles at two opposite edges are provided, in this case, the longitudinal edges, using milling devices which are positioned at different angles in reference to or about the panel. In contrast, during the second movement, profiles are provided at the other edges, in this case, the small edges, by further milling devices positioned at different angles in reference to the panel. During each of the aforementioned milling cycles, preferably substantially, the final form of one flank, either of the tongue or the groove, is realized.

[07] Similar panels allow for coupling using profiled edges, such as basic click panels, drop click panels, and other panels arranged for folding down (i.e., fold-down type). The profiled edges are commonly made as coupling parts with milling tools, as in WO 97/47834. However, a general problem is that residual portions can be at the corners of such panels when the coupling parts have different dimensions. At least in these circumstances, left-over pieces may remain at the corner after the second pair of opposite edges is milled. Such a left-over piece can cause problems in subsequent production steps, for example, where a coating agent, impregnation agent, paint, etc., is applied to the edges of the panel. In particular, the left-over pieces may come loose at the height of the machines of the subsequent production steps and can block the nozzles of these machines, pollute a material being applied, or otherwise interrupt the intended production.

[08] To remedy this disadvantage, techniques have already been considered where a so- called additional jumper is used to cut off these pieces. As is known in milling technology, a jumper is a tool that, at the appropriate times, makes a cutting or movement action towards the panel edge to cut off or knock away the left-over piece, such as at the corner. The use of a jumper or related device necessarily requires the use of an additional machine in the milling process, requiring additional space and expense in a manufacturing assembly. As well, particularly precise settings are required to prevent the jumper from damaging the coupling parts.

[09] SUMMARY

[10] It is an object of the disclosure to offer a solution for one or more problems encountered with prior-art panels and related processes. [11] According to a first aspect, the present disclosure relates to a method for manufacturing panels that allows obtaining a better and/or cheaper and/or more flexible and/or more reliable finishing of the coupling parts on the edges of the panels. The disclosure also relates to a method for designing such a panel and a panel obtained by such methods.

[12] In one aspect, the disclosure relates to a panel for forming a covering having an upper side defining an upper plane and an opposite lower side. The panel may include a first pair of opposite edges and a second pair of opposite edges. The first pair of opposite edges may be provided with coupling parts in the form of a tongue at one edge of the first pair of opposite edges and a groove at the other edge of the first pair of opposite edges. The groove may be bordered by an upper lip and a lower lip, wherein the lower lip distally extends beyond the upper lip. The second pair of opposite edges may be provided with coupling parts in the form of a male coupling part at one edge of the second pair of opposite edges and a female coupling part at the other edge of the second pair of opposite edges. The tongue may include a recess opposite the upper side of the panel and configured to receive a portion of the lower lip in a coupled condition. Preferably, the lower lip comprises an upwardly pointing interlocking part, wherein the recess is configured to receive the upwardly pointing interlocking part. This upwardly pointing interlocking part preferably forms the distal part of the lower lip. The panel thus makes it possible to form an interlocking tongue and groove connection between one of the first pair of opposite edges of the panel and another edge of similar panels, for example, the other of the first pair of opposite edges of a similar panel.

[13] The male coupling part at one edge of the second pair of opposite edges and a female coupling part at the other edge of the second pair of opposite edges could be in the form of a tongue and groove, wherein said groove may be bordered by an upper lip and a lower lip, wherein the lower lip distally extends beyond the upper lip. Two panels can then be couplable to each other at the height of corresponding first pair of opposite edges by a rolling/turning/angling movement or a horizontal shifting/sliding movement, and at the height of corresponding second pair of opposite edges also by a rolling/turning/angling movement or a horizontal shifting/sliding movement. The panels could also be configured in such a way that they are mutually couplable according to the so-called fold-down principle. On the first pair of opposite edges, the panels are then couplable to each other by a rolling/turning/angling motion, and on the second pair of opposites edges the panels are couplable to each other by a downward motion, wherein the downward motion could be a result of the rolling/turning/angling motion and so takes place substantially at the same time.

[14] This interlocking connection may result in a stable unit of coupled panels with a horizontal and/or vertical interlocking. In this case, it should be noted that the expression horizontal interlocking is understood to mean an interlocking that is active in the horizontal direction or the direction in the plane of the coupled panels and at right angles to the coupled edges. A vertical interlocking is understood to mean an interlocking that is active in the vertical direction or the direction at right angles to the plane of the coupled panels.

[15] In some embodiments, a groove depth measured between the upper plane of the panel and the lowest point of the groove is less than the vertical height of the male part measured between the lowest point of the male part and the upper side of the panel. When the panels are coupled, the upper plane of the panel is preferably parallel to the plane of the coupled panels. The groove depth is thus a dimension in the vertical direction, and the vertical height of the male part is thus a dimension in the vertical direction. The difference in the groove depth and the vertical height of the male part may tend to result in a left-over piece at a corner of the panel after the panel is milled, absent an adaptation according to the current disclosure. An adaptation may be provided in the form of a cut-out in the lower lip and facing the groove, such that a cut-out depth measured between the upper plane and the lowest cut-out point is greater than the vertical height of the male part. When the panels are coupled, the upper plane of the panel is preferably parallel to the plane of the coupled panels. The cut-out depth is thus a dimension in the vertical direction. The cut-out can form a channel, groove, recess or the like, and is distinct from the profile of the groove and preferably does not participate in the coupling of the tongue and groove. It is an advantage of the present disclosure that the adaptation removes or prevents left-over pieces in the comer of the panel, for example, where the groove of the first pair of opposite edges and the male part of the second pair of opposite edges intersect.

[16] The difference between the groove depth and the vertical height of the male part can be at most 1 mm, preferably at most 0.5 mm, more preferably at most 0.3 mm, and most preferably at most 0.1 mm.

[17] The total height of the panel can be between 3,20 mm and 10 mm, for example between 3.50 mm and 6 mm or between 4.50 mm and 8 mm or between 6 mm and 7 mm. The cut-out depth can be 0.1 mm greater than the vertical height of the male part, or between 0.1 mm and 0 mm greater, or more than 0.1 mm greater. For example the cut-out depth can be 0.5 mm or 0.8 mm or 1.2 mm or 1.4 mm or 1.6 mm greater than the vertical height of the male part.

[18] In another aspect, a recess depth measured between the upper side of the panel and the uppermost point of the recess is greater than a vertical height of the female part measured between an uppermost point of the female part and the upper plane. When the panels are coupled, the upper plane of the panel is preferably parallel to the plane of the coupled panels. The recess depth is thus a dimension in the vertical direction, and the vertical height of the female part is thus a dimension in the vertical direction. The difference in the recess depth and the vertical height of the female part may tend to result in a left-over piece at a corner of the panel after the panel is milled, absent an adaptation according to the current disclosure. An adaptation may be provided in the form of a cutout in the tongue and facing the recess. This cut-out can have, at the height of the recess, approximately the same width as the recess, such that a smooth transition between the recess and cut-out is possible, and the recess and the cut-out together have the appearance of a bigger/deeper/expanded recess. Of course, the cut-out can have, at the height of the recess, a smaller width than the recess. The width is preferably the dimension according to the horizontal direction. A vertical height of the cut-out measured between the upper side, e.g. the upper plane, of the panel and an uppermost point of the cut-out is less than the vertical height of the female part. When the panels are coupled, the upper plane of the panel is preferably parallel to the plane of the coupled panels. The vertical height of said cut-out is thus a dimension in the vertical direction. An advantage of the present disclosure is that the adaptation removes or prevents left-over pieces in the comer of the panel, where the tongue of the first pair of opposite edges and the female part of the second pair of opposite edges intersect.

[19] The difference between the recess depth and the vertical height of the female part can be at most 1 mm, preferably at most 0.5 mm, more preferably at most 0.3 mm, and most preferably at most 0.1 mm.

[20] The total height of the panel can be between 3,20 mm and 10 mm, for example between 3.50 mm and 6 mm or between 4.50 mm and 8 mm or between 6 mm and 7 mm.

The cut-out depth can be 0.1 mm less than the vertical height of the female part, or between 0.1 mm and 0 mm less, or more than 0.1 mm less. For example the cut-out depth can be 0.5 mm or 0.8 mm or 1.2 mm or 1.4 mm or 1.6 mm less than the vertical height of the male part.

[21] It is an advantage of the panel of the disclosure that a left-over piece may be removed or prevented from occurring in one or more corners of the panel without the need for a so- called “jumper” device or another cutting device. Instead, the left-over piece may be removed as part of a milling operation of the panel forming the coupling parts.

[22] Preferably a cut-out, according to the disclosure, is positioned to avoid participation in the coupling of the panels and has a small size to limit any effect on the coupling strength of the panels and reduce the amount of material that must be removed to form the cut-out. In certain aspects, the cut-out may be provided in the lower lip of the groove at a position that is distally located relative to the upper lip and a coupling plane defined by the upper lip. A cut-out in the lower lip and facing the groove, preferably is located between the coupling plane and the upwardly pointing interlocking part (if present). The closer said cut-out is located near the coupling plane, the bigger the part that is cut off during milling, the closer the said cut-out is located near the upwardly pointing interlocking part, the less impact upon the coupling strength. If the cut-out is located between the coupling plane and the upwardly pointing interlocking part, then the cut-out, seen according to the horizontal direction, can be located in the half located closest to the coupling plane, or in the half located closest to the upwardly pointing interlocking part or centrally and/or the distance between the cut-out and the coupling plane can be 0.3 mm or 0.5 mm or 0.7 mm or 1 mm or more than 1 mm.

[23] It is noted that the male coupling part and the female coupling part of the second pair of opposite edges may be a tongue and a groove, respectively. Other types of coupling parts are not excluded. The coupling parts of the second pair of opposite edges could for example be couplable by a rolling/turning/angling movement or a horizontal shifting/sliding movement.

[24] The male coupling part and the female coupling part of the second pair of opposite edges may be a downward directed upper hook-shaped portion and an upward directed lower hook-shaped portion. The lower hook-shaped portion could comprise a lip with an upward directed locking element that defines, proximally thereto, a female part in the form of a recess, while the upper hook-shaped portion comprises a lip with a downward directed locking element that forms a male part. These coupling parts could be connected to each other by a downward movement. Preferably the coupling parts of the first pair of opposite edges are then preferably couplable to each other by a rolling/turning/angling movement, such that in the same rolling/turning/angling movement, also coupling parts of the second pair of opposite edges are coupled to each other.

[25] The panel may preferably be configured as a laminate panel, a resilient panel, or the like. Thus, providing the panel as a floor, wall, or ceiling panel becomes possible. Other types of panels are not excluded.

[26] The panel is preferably a decorative panel. A decorative panel is provided with a decor on its upper side, which is visible in the installed position. The decor may be any kind, such as wood or stone decor. [27] A substrate of the panel may comprise wood. The substrate may, for example, comprise several wooden slats connected to each other. This is typically the case with engineered wood. However, the substrate may also be formed as a single part made of wood, for example, solid wood.

[28] The substrate of the panel may comprise wood particles and a binder for mutually binding the wood particles. Such a substrate is a wood-based substrate. The wood particles may be wood fibers and/or wood chips. The binder may be a glue or resin, such as melamine urea-formaldehyde, urea-formaldehyde, or isocyanate resin. Bio-based resins, such as resins comprising sugar, lignin, amines and/or flour are also possible. The substrate comprises, for example, a wood fiberboard, such as Medium Density Fiberboard (MDF) or High-Density Fiberboard (HDF), or a chipboard. One or more resin impregnated papers could be laminated upon such a wood-based substrate. Other layers are also possible. A veneer layer or timber layer could be attached to the wood-based substrate.

[29] The substrate of the panel may comprise a thermoplastic material. The thermoplastic material comprises a thermoplastic. The thermoplastic may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), or polyethylene terephthalate (PET). The thermoplastic material may comprise polyvinyl chloride, or another thermoplastic, with or without plasticizers. The thermoplastic material may or may not be foamed. The thermoplastic material may comprise closed-cell or open-cell foam. The thermoplastic material may comprise a filler. The filler may be an organic filler, such as wood particles. The filler may be an inorganic and/or mineral filler. The filler may be a mineral filler, such as calcium carbonate, chalk or limestone. The filler may be talc.

[30] The substrate of the panel may comprise a thermosetting material. The thermosetting material comprises a thermosetting plastic. The thermosetting plastic may be polyurethane (PU). The thermosetting material may comprise a filler. The filler may be an organic filler, such as wood particles. The filler may be an inorganic filler. The filler may be a mineral filler, such as calcium carbonate, for example chalk or limestone. The filler may be talc. [31 ] The substrate of the panel may comprise any desired other material, such as a cement fiber panel or a magnesium panel.

[32] The panel may be formed as a single part. The panel may, for example, be formed as a single part made of wood. This is the case, for example, with solid parquet. The panel could be a multi-layered panel, for example a laminate panel comprising a wood-based substrate and several resin impregnated papers or a resilient panel comprising several layers comprising thermoplastic material.

[33] The disclosure also relates to a method for manufacturing a panel with an adaptation in the form of a cut-out. The method comprises at least the following steps: advancing a panel relative to a first milling device having at least two milling tools, the panel having an upper side defining an upper plane; treating a first pair of opposite edges of the panel using the at least two milling tools of the first milling device to form coupling parts in the form of a tongue at one edge of the first pair of opposite edges and a groove at the other edge of the first pair of opposite edges, the groove being bordered by an upper lip and a lower lip, wherein said lower lip distally extends beyond the upper lip, and the tongue defines a recess opposite the upper side of the panel and configured to receive a portion of the lower lip; wherein: the lower lip includes a cut-out facing the groove, such that a cut-out depth measured between the upper plane and a lowest point of the cut-out is greater than a vertical height of the male part measured between a lowest point of the male part and the upper side of the panel; and/or the tongue further includes a cut-out facing the recess, such that a vertical height of the cut-out measured between the upper side of the panel and an uppermost point of the cut-out is less than a vertical height of the female part measured between an uppermost point of the female part and the upper plane. [34] Forming coupling parts using cutting or milling operations efficiently produces an accurate result. The cutting or milling tools are preferably rotating cutting or milling tools.

[35] Thus, the tongue and the groove may be formed, for example, using one or several cutting or milling tools, for example some or all of the cutting or milling tools can be stationary cutting or milling tools. A stationary cutting or milling tool is a cutting or milling tool which has a base part and/or axis with a fixed position during milling and is thus not moved towards or away from the panel during milling. In this case, the cutting or milling tool can rotate or perform a local cutting movement. After the treatment or treatments using one or several cutting or milling tools, a cut-out may be present along the entire or virtually the entire respective edge. The cutting or milling tools do not have to be stationary during milling. Between milling actions, the said base part and/or axis could be displaced and this to mill other profiles.

[36] Preferably, the method comprises the further steps: advancing the panel relative to a second milling device having at least two milling tools; and treating the second pair of opposite edges of the panel using the at least two milling tools of the second milling device to form coupling parts in the form of a male coupling part at one edge of the second pair of opposite edges and a female coupling part at the other edge of the second pair of opposite edges.

[37] The tongue on the one of the first pair of opposite edges may be formed using cutting or milling tools, for example some or all of the cutting or milling tools can be stationary cutting or milling tools. This may efficiently ensure these elements are present along the entire or virtually the entire edge of the first pair of opposite edges.

[38] The groove on the other of the first pair of opposite edges may be formed using one or several cutting or milling tools, for example stationary cutting or milling tools. This may efficiently ensure that this element is present along the entire or virtually the entire other edge of the first pair of opposite edges. [39] The male coupling part and the female coupling part on the one and/or other of the second pair of opposite edges may be formed using one or several cutting or milling tools, for example stationary cutting or milling tools. This may efficiently ensure that this element is present along the entire or virtually the entire edges of the second pair of opposite edges.

[40] In another aspect, the disclosure relates to manufacturing a panel where a left-over piece in a corner of the panel is prevented or removed by moving a milling tool. The method comprises at least the following steps: advancing a panel relative to a first milling device having at least two milling tools, the panel having an upper side defining an upper plane; treating a first pair of opposite edges of the panel using the at least two milling tools of the first milling device to form coupling parts in the form of a tongue at one edge of the first pair of opposite edges and a groove at the other edge of the first pair of opposite edges, the groove being bordered by an upper lip and a lower lip; advancing the panel relative to a second milling device having at least two milling tools; treating the second pair of opposite edges of the panel using the at least two milling tools of the second milling device to form coupling parts in the form of a male coupling part at one edge of the second pair of opposite edges and a female coupling part at the other edge of the second pair of opposite edges; wherein a milling tool of the at least two milling tools of the first milling device and/or of the at least two milling tools of the second milling device is moved in a vertical direction concerning the upper side of the panel during treatment of a corner region defined by an overlap of one of the first pair of opposite edges and one of the second pair of opposite edges, such that a corner piece is removed or prevented.

[41] Preferably, at least one of the cutting or milling tools is moved toward the panel in a vertical direction relative to the upper side of the panel during the milling of a corner region of the panel. This means that a part of the cutting tool and/or the axis of rotation of the milling tool can be moved in a vertical direction. This makes it possible for this cutting or milling tool to make locally a deeper cut at the height of a corner of the panel, which is advantageous for removing an excess material portion at a corner of the panel without impacting the profile of the coupling parts.

[42] Moving cutting or milling tools may be used on the first pair of opposite edges and/or the second pair of opposite edges. Preferably, one or several moving cutting or milling tools are used on the edges where a left-over piece may be present or has to be removed. A combination of stationary and moving cutting or milling tools may be used for manufacturing the panels according to this aspect of the disclosure.

[43] In another aspect, the disclosure relates to a method for designing a panel where a left-over piece in a corner of the panel is prevented or removed. The panel may have an upper side defining an upper plane and includes a first pair of opposite edges and a second pair of opposite edges. The first pair of opposite edges may be provided with coupling parts in the form of a tongue at one edge of the first pair of opposite edges and a groove at the other edge of the first pair of opposite edges, the groove being bordered by an upper lip and a lower lip, wherein said lower lip distally extends beyond the upper lip. The second pair of opposite edges may be provided with coupling parts in the form of a male coupling part at one edge of the second pair of opposite edges and a female coupling part at the other edge of the second pair of opposite edges. The method comprises at least the following steps: determining a groove depth measured between the upper plane and the lowest point of the groove; determining a vertical height of the male part measured between the lowest point of the male part and the upper side of the panel; determining a recess depth measured between the upper side of the panel and a highest point of the recess; determining a vertical height of the female part measured between an uppermost point of the female part and the upper plane; adding a lower cut-out to the lower lip when the groove depth is less than the vertical height of the male part, the lower cut-out facing the groove, and having a depth measured between the upper plane and the lowest point of the lower cut-out that is greater than the vertical height of the male part; and adding an upper cut-out to the tongue when the recess depth is greater than the vertical height of the female part, the upper cut-out facing the recess, and having a vertical height measured between the upper side of the panel and an uppermost point of the upper cutout that is less than the vertical height of the female part.

[44] The method of designing the panel may be performed automatically during a method of forming the panel, such as using a computer-controlled design program. As such, an improved panel may be achieved according to embodiments of the disclosure.

[45] This summary is provided to introduce a selection of concepts in a simplified form, further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an indication of the scope of the claimed subject matter.

[46] Additional features and advantages of the disclosure will be outlined in the following description and, in part, will be obvious from the description or may be learned by the practice of the disclosure. The features and advantages of the disclosure may be realized and obtained using the instruments and combinations particularly pointed out in the appended claims. These and other features of the present disclosure will become more apparent from the following description and appended claims or may be learned by the disclosure practice as set forth hereinafter.

[47] BRIEF DESCRIPTION OF DRAWINGS

[48] To show the features of the invention in more detail, some preferred embodiments are described below by way of example and without being limited thereto, concerning the accompanying drawings.

[49] Fig. 1 is a schematic view illustrating a method according to an aspect of the disclosure. [50] Fig. 2 is a perspective view of a panel when profiles are not adapted, and corner pieces are present.

[51] Fig. 3 A is a cross-sectional view along the intersecting line III-III in Fig. 2,

[52] Fig. 3B is a cross-sectional view of a groove coupling part adapted according to aspects of the current disclosure, with a profde of a neighboring male coupling part overlaying the groove coupling part in broken lines.

[53] Fig. 4 is a cross-sectional view along the intersecting line III-III in Fig. 2, where a milling operation provides an adaptation.

[54] Fig. 5A is a cross-sectional view similar to Fig. 3A for an opposite comer of the panel of Fig. 2.

[55] Fig. 5B is a cross-sectional view of a tongue coupling part adapted according to aspects of the current disclosure, with a profile of a neighboring female coupling part overlaying the tongue coupling part in broken lines.

[56] Fig. 6 is a cross-sectional view similar to Fig. 4, where a milling operation provides an adaptation for an opposite corner of the panel of Fig. 2.

[57] Fig. 7 is a perspective view of a panel when profiles are adapted, and corner pieces are not present.

[58] Fig. 8 is a cross-sectional view showing the coupling parts of the first pair of opposite edges in a coupled condition.

[59] Fig. 9 is a cross-sectional view along the intersecting line III-III in Fig. 2, demonstrating a plurality of possible adaptations.

[60] Fig. 10 is a cross-sectional view similar to Fig. 4, according to a variant where a milling operation, including a vertical movement, provides an adaptation.

[61] Fig. 11 is a perspective view similar to Fig. 7 according to the variant of Fig. 10.

[62] Fig. 12 is a perspective view of a panel variant when profiles are not adapted, and corner pieces are present. [63] Fig. 13 is a cross-section view similar to Fig. 4, showing an adaptation provided by a milling operation for the panel of Fig. 12.

[64] Fig. 14 is a perspective view of the panel of Fig. 12, where the profiles are adapted, and the corner pieces are not present.

[65] DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

[66] Overview

[67] A better understanding of different embodiments of the disclosure may be had from the following description and accompanying drawings in which reference characters refer to like elements.

[68] While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. It should be understood that there is no intention to limit the disclosure to the specific embodiments disclosed, but on the contrary, the intention covers all modifications, alternative constructions, combinations, and equivalents falling within the spirit and scope of the disclosure.

[69] It will be understood that unless a term is expressly defined in this application to possess a described meaning, there is no intent to limit the meaning of such term, either expressly or indirectly, beyond its plain or ordinary meaning.

[70] Any element in a claim that does not explicitly state "means for" performing a specified function or "step for" performing a specific function is not to be interpreted as a "means" or "step" clause as specified in 35 U.S.C. § 112.

[71] Various Embodiments

[72] Fig. 1 schematically shows how a panel 10 can be obtained using a method according to the first aspect of the present disclosure. In the represented example, using two processing machines, more particularly continuous milling machines 50, 51, the panel 10 is provided with coupling parts at a first pair of opposite edges 14, 15 of the panel and at a second pair of opposite edges 56, 57. Herein, the so-called “continuous milling” is applied. Initially, the panel 10 is moved with the first pair of opposite edges 14, 15 over the mechanical cutting tools 52a, 52b. Then the second pair of opposite edges 56, 57 are subjected to similar treatments.

[73] It is noted that, although shown as a rectangular panel 10 in the depicted embodiment of Fig. 1, the panel 10 may be rectangular or square. The panel 10 is preferably displaced using two sequential perpendicular movements, VI and V2, whereby during the first movement, VI profiles are provided at the first pair of opposite edges 14, 15, in the illustrated case, the longitudinal edges, using the mechanical cutting tools 52a, 52b, whereas during the second movement V2 profiles are provided at the second pair of opposite edges 56, 57, in the illustrated case the transverse or short edges, using the mechanical cutting tools 52a, 52b. During this processing, the panel 10 is preferably oriented with an upper side of the panel 10 directed downward, such that a lower side 11 of the panel 10 is shown in the illustrated example.

[74] The represented panel 10 may comprise any suitable material for use in panels, such as forming a laminate panel, a resilient panel, or the like. Other types of panels are not excluded. Accordingly, the panel 10 may comprise a substrate where coupling parts of two edges meet at a corner, as would be apparent to one skilled in the art from the instant disclosure.

[75] The panel is preferably a decorative panel. A decorative panel is provided with a decor on its upper side, which is visible in the installed position. The decor may be any decor, such as wood or stone decor.

[76] A substrate of the panel may comprise wood. The substrate may, for example, comprise several wooden slats connected to each other. This is typically the case with engineered wood. However, the substrate may also be formed as a single part made of wood, for example, solid wood.

[77] The substrate of the panel may comprise wood particles and a binder for mutually binding the wood particles. The wood particles may be wood fibers and/or wood chips. The binder may be a glue or resin, such as melamine, formaldehyde, or isocyanate resin. The substrate comprises, for example, a wood fiberboard, such as Medium Density Fiberboard (MDF) or High-Density Fiberboard (HDF), or a chipboard.

[78] The substrate of the panel may comprise a thermoplastic material. The thermoplastic material comprises a thermoplastic. The thermoplastic may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), or polyethylene terephthalate (PET). The thermoplastic material may comprise polyvinyl chloride with or without plasticizers. The thermoplastic material may or may not be foamed. The thermoplastic material may comprise closed-cell or open-cell foam. The thermoplastic material may comprise a filler. The filler may be an organic filler, such as wood particles. The filler may be inorganic. The filler may be a mineral filler, such as calcium carbonate, for example chalk or limestone. The filler may be talc.

[79] The substrate of the panel may comprise a thermosetting material. The thermosetting material comprises thermosetting plastic. The thermosetting plastic may be polyurethane (PU). The thermosetting material may comprise a filler. The filler may be an organic filler, such as wood particles. The filler may be inorganic. The filler may be a mineral filler, such as calcium carbonate, for example, chalk or limestone. The filler may be talc.

[80] The substrate of the panel may comprise any desired other material, such as a cement fiber panel or a magnesium panel.

[81] The panel may be formed as a single part. The panel may, for example, be formed as a single part made of wood. This is the case, for example, with solid parquet. The panel could be a multi-layered panel.

[82] According to an aspect of the disclosure, the profiles of the edges 14, 15, 56, 57 are formed using a milling process with a plurality of sequential milling cycles or passes using the mechanical cutting tools 52a, 52b or milling cutters which are positioned at different angles about the related panel 10. A tongue 16 and a groove 17 may be provided as corresponding coupling parts to the first pair of opposite edges 14, 15 using between 2 and 8 milling cycles for example four or six milling cycles using milling tools or cutters. [83] A panel 10 having coupling parts according to the current disclosure may be formed by advancing the panel 10 relative to a first milling device 50 having at least two milling tools 52a, 52b. The milling tools 52a, 52b may be positioned at opposite edges of the panel 10 to simultaneously treat both opposite edges 14, 15 of the panel 10. Milling tools, according to some embodiments, may be provided as rotating milling tools and may be stationary cutting tools during milling, for example with an axis of rotation which has a fixed position during use, or may be moveable in a horizontal direction parallel to a plane of the panel. While the panel 10 advances through the first milling device 50, the first pair of opposite edges 14, 15 is treated to form coupling parts. Each milling tool may form a face or flank of a respective tongue or groove as the panel passes the milling tool in sequential milling cycles. Such a cut-out can be made by a separate milling tool. However preferably, such a cut-out 22, 35 is made by a milling tool which also forms another face or flank of a respective tongue or groove. It is also possible that parts of said cut-outs 22, 35 are made with different milling tools.

[84] The perspective view of the underside of the panel 10 in Fig. 2 shows that the profiled edge regions formed of the edges 14, 15, 56, 57 of the panel 10 during milling operations comprise coupling parts, more particularly in the form of a tongue 16 and a groove 17 at the first pair of opposite edges 14, 15 and in the form of a female coupling part 28 and a male coupling part 29 at the second pair of opposite edges 56, 57. As shown in Fig. 3A, the groove 17 is bordered by a lower lip 18 and an upper lip 19, whereby in the illustrated example, the lower lip 18 extends beyond the upper lip 19 and comprises an upwardly pointing interlocking part which forms the moist distal point of the lower lip 18. In a coupled condition of at least two of the aforementioned panels 10, which is discussed further concerning Fig. 8, the represented tongue 16 and groove 17 result in a mutual locking of the respective panels 10, in a horizontal as well as in a vertical direction. Of course, other coupling parts are possible according to different variants of the disclosure, and features of the detailed embodiments may be equally applicable to such different types of coupling parts. The panel 10 shown in Fig. 2 is configured in such a way that such panels 10 are mutually couplable according to the so-called fold-down principle. [85] The panel 10 may be advanced relative to a second milling device 51 having at least two milling tools 52a, 52b, such as positioned at opposite edges of the panel to treat both opposite edges 56, 57 simultaneously. While the panel 10 advances through the second milling device 51, the second pair of opposite edges 56, 57 is treated to form coupling parts, the coupling parts of the second pair of opposite edges 56, 57 provided in the form of a male coupling part 29 at one edge 56 of the second pair of opposite edges and a female coupling part 28 at the other edge 57 of the second pair of opposite edges 56, 57. The male coupling part 29 and the female coupling part 28 of the second pair of opposite edges 56, 57 are a downward directed upper hook-shaped portion and an upward directed lower hook-shaped portion. The lower hook-shaped portion comprises a lip with an upward directed locking element that defines, proximally thereto, a female part in the form of a recess, while the upper hook-shaped portion comprises a lip with a downward directed locking element that forms a male part. As noted previously, other coupling parts are possible according to different variants of the disclosure, and features of the detailed embodiments may be equally applicable to such different types of coupling parts.

[86] As becomes quite clear from Fig. 2, problems can arise at corners 60 of the panel 10 for coupling parts having certain dimensions or thicknesses, resulting in left-over pieces 30, 31 remaining attached to the panel 10. In the illustrated examples, the left-over piece 30 is found at the corner where the groove 17 of the first pair of opposite edges 14, 15 and the male coupling part 29 of the second pair of opposite edges 56, 57 come together, while the left-over piece 31 is found at the corner where the tongue 16 of the first pair of opposite edges 14, 15 and the female coupling part 28 of the second pair of opposite edges 56, 57 come together. This result may occur due to an overlap in a thickness of the corresponding profiled edges, such that a material portion A, B remains to connect the left-over pieces 30, 31 to the panel 10 following the standard milling operations.

[87] Fig. 3 A provides a cross-section III -III of Fig. 2, reoriented to show an upper side 13 and a lower side 11 of the panel 10. The depicted panel 10 includes the groove 17, which is bordered by the lower lip 18 and the upper lip 19, such that a groove depth 20 measured between an upper plane 48 of the panel 10 and a lowest point 21 of the groove 17 is less than a vertical height 32 of the male part 29 measured between a lowest point 33 of the male part 29 and an upper side 13 of the panel 10. A difference between the groove depth 20 and the vertical height 32 of the male part 29 results in a material portion A that may remain after a milling process, such that left-over piece 30 is retained at the corner of the panel 10.

[88] In varying embodiments, the difference between the groove depth 20 and the vertical height 32 of the male part 29 may be no more than 1 mm, preferably no more than 0.5 mm, more preferably no more than 0.3 mm, and most preferably no more than 0.1 mm. It should be noted that such a limited amount of material remains problematic due to a tendency to detach from the panel 10 at unpredictable moments and can leave a dangerously sharp edge or otherwise damage the profiled edge if pulled or caught.

[89] As discussed previously, it is preferred that the left-over piece 30 be removed during the milling process, without the need for additional components or interventions. In an embodiment of a method of the current disclosure, the first pair of opposite edges 14, 15 may be treated using the at least two milling tools 52a, 52b of the first milling device 50 to form coupling parts in the form of the tongue 16 at one edge 14 of the first pair of opposite edges and a groove 17 at the other edge 15 of the first pair of opposite edges, the groove 17 being bordered by the upper lip 19 and the lower lip 18. In the treatment of the first pair of opposite edges 14, 15, one or more of milling tools may be adapted to form one or more of: a cut-out in the lower lip and facing the groove, such that a cut-out depth measured between the upper plane and a lowest point of the cut-out is greater than a vertical height of the male part measured between a lowest point of the male part and the upper side of the panel; and a cut-out in the tongue and facing a recess of the tongue, such that the vertical height of the cut-out measured between the upper side of the panel and an uppermost point of the cut-out is less than the vertical height of the female part measured between an uppermost point of the female part and the upper plane. [90] Fig. 3B shows a cross-section of the groove 17 with a profile of the male coupling part 29 in broken lines overlaying the groove 17. According to an aspect of the disclosure, the lower lip 18 may be adapted to include a cut-out 22 facing the groove 17 as shown in Fig. 3B. A cut-out depth 23 measured between the upper plane 48 and a lowest point 24 of the cut-out 22 is thereby greater than the vertical height 32 of the male part 29 measured between the lowest point 33 of the male part 29 and the upper side 13 of the panel 10, such that the material portion A is removed by the cut-out 22 and the left-over piece 30 is prevented or removed according to Fig. 7.

[91] In varying embodiments, the cut-out depth 23 may be selected to ensure that the leftover piece 30 is removed while minimizing any loss of material strength in the lower lip 18 that may result from a cut-out 22 that is too deep. For example, the cut-out depth 23 may be 0.1 mm greater than the vertical height 32 of the male part 29, or between 0.1 mm and 0 mm greater, or more than 0.1 mm greater. Advantageously, the cut-out 22 does not participate in the coupling of the tongue 16 and the groove 17, such that the left-over piece 30 may be prevented or removed without affecting the coupling properties of the panel 10.

[92] The cut-out 22 may be made by modifying an existing milling operation or tool or adding a further milling operation or milling tool. Accordingly, an additional milling cutter 80 may be used as shown in Fig. 4 to form the cut-out 22, one or more of milling tools may form the cut-out during one of the milling cycles, or the cut-out 22 may be formed in a different milling cycle. Preferably, the cut-out 22 is formed in an existing milling cycle or at least in an existing milling device, such that the panel is efficiently manufactured without the need for additional space and expense.

[93] Fig. 5A provides a similar view as Fig. 3A but for the opposite corner of the panel 10. The depicted panel 10 includes the tongue 16, the tongue 16 defining a recess 25 configured to receive a portion of the lower lip 18 of the first pair of opposite edges, which lower lip is not shown in Fig. 5A. The lower lip 18 comprises an upwardly pointing interlocking part, wherein the recess 25 is configured to receive this upwardly pointing interlocking part. The recess 25 has a recess depth 26 measured between the upper side 1

13 of the panel 10 and an uppermost point 27 of the recess 25, the recess depth 26 being greater than a vertical height 34 of the female part 28 measured between an uppermost point 37 of the female part 28 and the upper plane 48 of the panel 10. A difference between the recess depth 26 and the vertical height 34 of the female part 28 results in a material portion B that may remain after a milling process, such that left-over piece 31 is retained at the corner of the panel 10.

[94] In varying embodiments, the difference between the recess depth 26 and the vertical height 34 of the female part 28 may be no more than 1 mm, preferably no more than 0.5 mm, more preferably no more than 0.3 mm, and most preferably no more than 0.1 mm. As noted previously, such a limited amount of material remains problematic due to a tendency to detach from the panel 10 at unpredictable moments and can leave a dangerously sharp edge or otherwise damage the profiled edge if pulled or caught.

[95] It is preferred that the left-over piece 31 be removed during the milling process without the need for additional components or interventions. Fig. 5B shows a cross-section of the tongue 16 with a profile of the female coupling part 28 in broken lines overlaying the tongue 16. According to an aspect of the disclosure, the tongue 16 may be adapted to include a cut-out 35 facing the recess 25 as shown in Fig. 5B. A vertical height 36 of the cut-out 35 measured between the upper side 13 of the panel 10 and an uppermost point 46 of the cut-out 35 is thereby less than the vertical height 34 of the female part 28 measured between the uppermost point 37 of the female part 28 and the upper plane 48 of the panel 10, such that the material portion B is removed by the cut-out 35 and the left-over piece 31 is prevented according to Fig. 7.

[96] In varying embodiments, the vertical height 36 of the cut-out 35 may be selected to ensure that the left-over piece 31 is removed while minimizing any loss of material strength in the tongue 16 that may result from a cut-out 35 that is too deep. For example, the cut-out depth 35 may be 0.1 mm less than the vertical height 34 of the female part 28, or between 0.1 mm and 0 mm less, or more than 0.1 mm less. Advantageously, the cutout 35 does not participate in the coupling of the tongue 16 and the groove 17, such that the left-over piece 31 may be removed or prevented without affecting the coupling properties of the panel 10. In certain embodiments, the cut-out 35 may expand the entire recess 25 or be provided as a more limited, local cut-out.

[97] The cut-out 35 may be made by modifying an existing milling operation or milling tool, or by adding a further milling operation or milling tool. Accordingly, an additional milling cutter 82 may be used as shown in Fig. 6 to form the cut-out 35, one or more of milling tools may form the cut-out during one of the milling cycles, or the cut-out 35 may be formed in a different milling cycle. Preferably, the cut-out 35 is formed in an existing milling cycle or at least in an existing milling device, such that the panel is efficiently manufactured without the need for a jumper or other device requiring additional space and expense.

[98] From Fig. 7, it is clear that left-over pieces 30 and 31 may be prevented or otherwise removed according to an aspect of the current disclosure. Of course, it may be possible that certain dimensions of coupling parts for a panel result in left-over pieces at only one corner, such that an aspect of the disclosed embodiments may relate to providing a cutout only on one of the first opposite edges 14, 15, or on both of the first opposite edges 14, 15.

[99] Fig. 8 represents two panels 10 in a coupled condition of the first pair of opposite edges, which are manufactured or adapted according to a method of the current disclosure. Herein, the tongue 16 and the groove 17 are provided as cooperating coupling parts. As shown in the depicted embodiment, the groove 17 may be bordered by a lower lip 18 and an upper lip 19, which include locking portions 38, 39 and a contact surface 40. The tongue 16 may include a corresponding contact surface 41 and locking portions 42, 43, configured to cooperate with the locking portions 38, 39 and the contact surface 40 in a coupled condition of the panels 10. In this case, the tongue 16 and the groove 17 may effect a coupling by a relative movement of the panels 10, for example a turning movement or a translational movement, and a click-fit, snap-fit or similar effect may or may not occur.

[100] As shown in the depicted embodiment of Fig. 8, one or both of the tongue 16 and the groove 17 may include a cut-out 22, 35. According to an aspect of the disclosure, the cut-out 22, 35 may not participate in the coupling of the panels 10. For example, while the cut-out 22 is shown as provided in the lower lip 18 the cut-out 22 does not interface or make contact with the tongue 16. In like manner, the cut-out 35 of Fig. 8 is shown as an expansion of the recess 25, wherein the locking portion 38 of the lower lip 18 does not enter the cut-out 35 in a coupled condition. It is noted that other forms of locking portions or tongue and groove profiles are not excluded.

[101] From Fig. 8 it is clear that a position, size, and shape of a cut-out may vary according to aspects of the current disclosure while still realizing the advantage of preventing or removing left-over pieces of material. Accordingly, a cut-out 35 may be a more localized cut-out, such as does not extend across the entire width of the recess 25. Similarly, a cutout 22 may be provided in the lower lip 18 in a location other than shown in the depicted embodiment, with corresponding differences in cut-out depth.

[102] In preferred embodiments, a cut-out 22 in the lower lip 18 is located distally from a closing plane 44 defined by contact surfaces 40, 41. Fig. 9 illustrates multiple alternatives for a cut-out 22a, 22b, 22c. As can be seen from Fig. 9, as a distance between a cut-out 22a, 22b, 22c and the closing plane 44 decreases, the quantity of material that must be removed to form the respective cut-out 22a, 22b, 22c increases to ensure that a cut-out depth 23 measured between the upper plane 48 of the panel 10 and a lowest point 24 of the cut-out 22a, 22b, 22c is greater than a vertical height 32 of the male part 29 measured between a lowest point 33 of the male part 29 and the upper side 13 of the panel 10. As more material is removed to form the cut-out 22a, 22b, 22c, more coupling strength is lost in the respective panel 10.

[103] In like manner, as a distance between a cut-out 22a, 22b, 22c and the closing plane 44 increases, the quantity of material that must be removed to form the respective cut-out 22a, 22b, 22c decreases. As such, the further the cut-out 22a, 22b, 22c is located from the closing plane 44, the less material must be removed to form the cut-out 22a, 22b, 22c, but less coupling strength is lost. [104] Preferably a cut-out, according to disclosed embodiments may be very small and have any shape that may be accomplished by milling. More particularly, it may be preferred that a cut-out have the necessary depth but a minimum width measured in a distal direction of the panel.

[105] Figs. 10-11 represents a variant of the disclosure where a direct milling operation may remove an excess material portion C without a change in a profile of a coupling part. According to this aspect of the disclosure, a milling tool 53 may be provided capable of moving vertically during a milling operation. For example, the milling tool 53 may be provided for milling the male coupling part 29 of the second pair of opposite edges 56, 57. During the milling operation of the edge 56, the milling tool 53 may be located at a first position 54, or height, and may be moved in a vertical direction towards the upper side 13 of the panel 10 to a second position 59, or height, when reaching a corner of the panel 10. The corner may be defined as a region of overlap in two edges 15, 56 of the panel 10.

[106] According to the aspect of Figs. 10-11, a left-over piece 30 may be removed or prevented due to the milling tool 53 removing or cutting the corner. In varying embodiments, the panel 10 may be moved in the vertical direction, such as by configuration of an air bed, belts, shoes, supports, or other components of a transport system for the milling operation and this for removing or cutting the corner. The operation, according to Figs. 10-11, may be performed and/or repeated during milling of the female coupling part 28 on the edge 57 for the left-over piece 31.

[107] In a related aspect, a milling tool may be moved in a vertical direction during a milling operation of the groove 17 of the first pair of opposite edges 14, 15. In this example, during the milling operation of the edge 15, the milling tool may be located at the first position 54, or height, and may be moved in a vertical direction towards the upper side 13 of the panel 10 to a second position 59, or height, when reaching a corner of the panel 10. In this manner, a left-over piece 30 may be removed or prevented due to the milling tool removing or cutting the corner, whether in total or in part. In some aspects, the movement of the milling tool may remove enough material that the milling tool 53 may complete the removal of the left-over piece 30 during milling of the male coupling part 29 without the need for a vertical movement. In a variant, the movement of the milling tool may substantially remove the left-over piece 30 before milling the male coupling part 29. The operation may be performed and/or repeated during the milling of the tongue 16 using a milling tool on the edge 14 for the left-over piece 31.

[108] As is clear from the disclosed aspects of Figs. 10-11, the removal or prevention of left-over pieces 30, 31 does not require using a separate so-called jumper device. Instead, as discussed above, a rotating milling tool may be provided that is configured to “jump” or move in the vertical direction, such that the milling tool cuts deeper at the corners of the panel, such that left-over pieces 30, 31 can no longer be present. Advantageously, the movement of the milling tool realizes the removal or prevention of left-over pieces 30, 31 at the corners of the panel 10 without requiring any adaptation of the coupling parts themselves. A similar result may be achieved with a transport system adapted to move the panel 10 in the vertical direction during the milling of the corners.

[109] Figs. 12-14 represent how aspects of the disclosure may be implemented for a panel 10, where the second pair of opposite edges 56, 57 is provided with different coupling parts. In the depicted example, both the first pair of opposite edges and the second pair of opposite edges 56, 57 include coupling parts in the form of a tongue 16, 56 and groove 17, 57. It is noted that the relative dimensions of the tongue 16, 56 and groove 17, 57 coupling parts may be configured to result in the removal or prevention of left-over pieces 55, however a sharp piece 58 may remain at the corners. As with other left-over pieces discussed herein, the sharp piece 58 may present problems for further processing of the panel 10 due to a tendency of the piece 58 to detach from the panel 10, such as during painting or coating operations, or to otherwise present a sharp edge that can injure an installer or damage the profiled edge if pulled or caught.

[110] Accordingly, one or both of the first pair of opposite edges 14, 15 may be adapted to include a cut-out 22 according to aspects of the disclosure previously discussed. As shown in Fig. 13, the cut-out 22 may be formed by a milling operation in a lower lip 18 of the groove 17. Of course, such a cut-out 22 may be provided in one or both of a tongue 16 and groove 17 of the first pair of opposite edges, as discussed concerning Figs. 3-8.

[111] As is clear from a comparison of Figs. 12 and 14, the cut-out 22 provides that the sharp piece 58 is removed from the panel 10, such that no sharp piece is present to fall off of the panel 10 during further processing or to cause damage to the panel or an installer. Notably, the disclosed aspects discussed concerning Figs. 10-11 may also be applied to a panel 10, according to Fig. 12, for achieving a removal of the sharp piece 58 without needing an independent jumper device or adapting a profile of the coupling parts.

[112] In another aspect, the disclosure relates to a method for designing a panel 10 where a left-over piece 30, 31 in a corner 60 of the panel 10 is prevented or removed. The panel 10 may have an upper side 13 defining an upper plane 48, the panel 10 comprising a first pair of opposite edges 14, 15 and a second pair of opposite edges 56, 57 as shown in the depicted embodiments.

[113] The first pair of opposite edges 14, 15 may be provided with coupling parts in the form of a tongue 16 at one edge 14 of the first pair of opposite edges and a groove 17 at the other edge 15 of the first pair of opposite edges, the groove 17 being bordered by an upper lip 19 and a lower lip 18, wherein said lower lip 18 distally extends beyond the upper lip 19. The second pair of opposite edges 56, 57 may be provided with coupling parts in the form of a male coupling part 29 at one edge 56 of the second pair of opposite edges 56, 57 and a female coupling part 28 at the other edge 57 of the second pair of opposite edges 56, 57.

[114] The panel 10 may be designed by: determining a groove depth 20 measured between the upper plane 48 and a lowest point 21 of the groove 17; determining a vertical height 32 of the male part 29 measured between a lowest point 33 of the male part 29 and the upper side 13 of the panel 10; determining a recess depth 26 measured between the upper side 13 of the panel 10 and an uppermost point 27 of the recess 25; determining a vertical height 34 of the female part 28 measured between an uppermost point 37 of the female part 28 and the upper plane 48; adding a lower cut-out 22 to the lower lip 18 when the groove depth 20 is less than the vertical height 32 of the male part 29, the lower cut-out 22 facing the groove 17 and having a depth 23 measured between the upper plane 48 and a lowest point 24 of the lower cut-out 22 that is greater than the vertical height 32 of the male part 29; and adding an upper cut-out 35 to the tongue 16 when the recess depth 26 is greater than the vertical height 34 of the female part 28, the upper cut-out 35 facing the recess 25 and having a vertical height 36 measured between the upper side 13 of the panel 10 and an uppermost point 46 of the upper cut-out 35 that is less than the vertical height 34 of the female part 28.

[115] The method of designing the panel may be performed automatically using a computer-controlled design program. Further, the method may be applied to a new or existing panel design, such that a manufacturing method or related milling system may be adapted to remove or prevent left-over pieces at the corners without the need for additional devices or processes. Instead, left-over pieces at the corners may be removed or prevented during the milling of the panel. As such, an improved panel may be achieved according to embodiments of the disclosure.

[116] The present invention is by no means limited to the above-described embodiments, but different variants of such panels may be produced without departing from the scope of the present invention. It is clear that further all aspects of the present invention that relate to a method can be combined in an unlimited manner, wherein then advantageous synergetic effects may or may not occur. Further, it is noted that the present invention also relates to panels that are realized according to any of the above methods or by a combination of the above-described methods.

Claims

1. A panel (10) for forming a covering having an upper side (13) defining an upper plane (48), wherein the panel (10) comprises a first pair of opposite edges (14, 15) and a second pair of opposite edges (56, 57); the first pair of opposite edges (14, 15) provided with coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18), wherein said lower lip (18) distally extends beyond the upper lip (19); the second pair of opposite edges (56, 57) provided with coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein the lower lip (18) includes a cut-out (22) facing the groove (17), such that a cut-out depth (23) measured between the upper plane (48) and a lowest point (24) of the cut-out (22) is greater than a vertical height (32) of the male part (29) measured between a lowest point (33) of the male part (29) and the upper side (13) of the panel (10).

2. The panel (10) according to claim 1, wherein a groove depth (20) measured between the upper plane (48) and a lowest point (21) of the groove (17) is less than the vertical height (32) of the male part (29).

3. The panel (10) according to any of the preceding claims, wherein a difference between the groove depth (20) and the vertical height (32) of the male part (29) is less than 1 mm.

4. The panel (10) according to any of the preceding claims, wherein the cut-out depth (23) is greater than the vertical height (32) of the male part (29) by at least 0.1 mm.

5. The panel (10) according to any of the preceding claims, wherein the cut-out (22) does not participate in a coupling of the first pair of opposite edges (14, 15).

6. The panel (10) according to any of the preceding claims, wherein the cut-out (22) is distally located relative to the upper lip (19).

7. The panel (10) according to any of the preceding claims, wherein a width of the cut-out (22) is less than 0.5 mm, preferably less than 0.3 mm, more preferably less than 0.1 mm.

8. The panel (10) according to any of the preceding claims, wherein the male coupling part (28) and the female coupling part (29) of the second pair of opposite edges (56, 57) comprise a tongue and a groove, respectively.

9. The panel (10) according to any of the preceding claims, wherein the panel (10) comprises a floor panel, a ceiling panel, or a wall panel.

10. The panel (10) according to any of the preceding claims, wherein the panel (10) is a laminate panel or a resilient panel.

11. A panel (10) for forming a covering having an upper side (13) defining an upper plane (48), wherein the panel (10) comprises a first pair of opposite edges (14, 15) and a second pair of opposite edges (56, 57); the first pair of opposite edges (14, 15) provided with coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18); the second pair of opposite edges (56, 57) provided with coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); wherein the tongue (16) further includes a cut-out (35) facing the recess (25), such that a vertical height (36) of the cut-out (35) measured between the upper side (13) of the panel (10) and an uppermost point (46) of the cut-out (35) is less than a vertical height (34) of the female part (28) measured between an uppermost point (37) of the female part (28) and the upper plane (48).

12. The panel (10) according to claim 11, wherein a recess depth (26) measured between the upper side (13) of the panel (10) and the uppermost point (27) of the recess (25) is greater than the vertical height (34) of the female part (28).

13. The panel (10) according to any of the preceding claims 11 to 12, wherein a difference between the recess depth (26) and the vertical height (34) of the female part (28) is less than 1 mm.

14. The panel (10) according to any of the preceding claims 11 to 13, wherein the vertical height (36) of the cut-out (35) is less than the vertical height (34) of the female part (28) by at least 0.1 mm. 15. The panel (10) according to any of the preceding claims 11 to 14, wherein the cut-out (35) does not participate in a coupling of the first pair of opposite edges (14,

15).

16. The panel (10) according to any of the preceding claims 11 to 15, wherein a width of the cut-out (35) is less than 0.5 mm, preferably less than 0.3 mm.

17. The panel (10) according to any of the preceding claims 11 to 16, wherein the male coupling part (29) and the female coupling part (28) of the second pair of opposite edges (56, 57) comprise a tongue and a groove, respectively.

18. The panel (10) according to any of the preceding claims 11 to 17, wherein the panel (10) comprises a floor panel, a ceiling panel, or a wall panel.

19. The panel (10) according to any of the preceding claims 11 to 18, wherein the panel (10) is a laminate panel or a resilient panel.

20. A panel (10) for forming a covering having an upper side (13) defining an upper plane (48), wherein the panel (10) comprises a first pair of opposite edges (14 ,15) and a second pair of opposite edges (56, 57); the first pair of opposite edges (14, 15) provided with coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18), wherein said lower lip (18) distally extends beyond the upper lip (19); the second pair of opposite edges (56, 57) provided with coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); wherein: the lower lip (18) includes a cut-out (22) facing the groove (17), such that a cut-out depth (23) measured between the upper plane (48) and a lowest point (24) of the cut-out (22) is greater than a vertical height (32) of the male part (29) measured between a lowest point (32) of the male part (29) and the upper side (13) of the panel (10); and/or the tongue (16) further includes a cut-out (35) facing the recess (25), such that a vertical height (36) of the cut-out (35) measured between the upper side (13) of the panel (10) and an uppermost point (46) of the cut-out (35) is less than a vertical height (34) of the female part (28) measured between an uppermost point (37) of the female part (28) and the upper plane (48).

21. A method for designing a panel (10), the panel (10) having an upper side (13) defining an upper plane (48), wherein the panel (10) comprises a first pair of opposite edges (14, 15) and a second pair of opposite edges (56, 57), the first pair of opposite edges (14, 15) provided with coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14 ,15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18), wherein said lower lip (18) distally extends beyond the upper lip (19), wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18), the second pair of opposite edges (56, 57) provided with coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57), the method comprising: determining a groove depth (20) measured between the upper plane (48) and a lowest point (21) of the groove (17); determining a vertical height (32) of the male part (29) measured between a lowest point (33) of the male part (29) and the upper side (13) of the panel (10); determining a recess depth (26) measured between the upper side (13) of the panel (10) and an uppermost point (27) of the recess (25); determining a vertical height (34) of the female part (28) measured between an uppermost point (37) of the female part (28) and the upper plane (48); adding a lower cut-out (22) to the lower lip (18) when the groove depth (20) is less than the vertical height (32) of the male part (29), the lower cut-out (22) facing the groove (17) and having a depth (23) measured between the upper plane (48) and a lowest point (24) of the lower cut-out (22) that is greater than the vertical height (32) of the male part (29); and adding an upper cut-out (35) to the tongue (16) when the recess depth (26) is greater than the vertical height (34) of the female part (28), the upper cut-out (35) facing the recess (25) and having a vertical height measured between the upper side (13) of the panel (10) and an uppermost point (46) of the upper cut-out (35) that is less than the vertical height (34) of the female part (28).

22. The method according to claim 21, wherein a difference between the groove depth (20) and the vertical height (32) of the male part (29) is less than 1 mm.

23. The method according to any of the preceding claims 21 to 22, wherein the depth (23) of the lower cut-out (22) is greater than the vertical height (32) of the male part (29) by at least 0.1 mm.

24. The method according to any of the preceding claims 21 to 23, wherein the lower cutout (22) does not participate in a coupling of the first pair of opposite edges (14, 15).

25. The method according to any of the preceding claims 21 to 24, wherein a difference between the recess depth (26) and the vertical height (34) of the female part (28) is less than 1 mm.

26. The method according to any of the preceding claims 21 to 25, wherein the vertical height (36) of the upper cut-out (35) is less than the vertical height (24) of the female part (28) by at least 0.1 mm.

27. The method according to any of the preceding claims 21 to 26, wherein the upper cutout (35) does not participate in a coupling of the first pair of opposite edges (14, 15).

28. The method according to any of the preceding claims 21 to 27, wherein a width of the upper cut-out (35) is less than 0.5 mm.

29. The method according to any of the preceding claims 21 to 28, wherein a width of the lower cut-out (22) is less than 0.5 mm, preferably less than 0.3 mm.

30. The method according to any of the preceding claims 21 to 29, wherein the male coupling part (29) and the female coupling part (28) of the second pair of opposite edges (56, 57) comprise a tongue and a groove, respectively.

31. A method for manufacturing a panel (10), the method comprising: advancing a panel (10) relative to a first milling device having at least two milling tools, the panel (10) having an upper side (13) defining an upper plane (48); treating a first pair of opposite edges (14, 15) of the panel (10) by means of the at least two milling tools of the first milling device to form coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18), wherein said lower lip (18) distally extends beyond the upper lip (19); advancing the panel (10) relative to a second milling device having at least two milling tools; treating a second pair of opposite edges (56, 57) of the panel (10) by means of the at least two milling tools of the second milling device to form coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); wherein: the lower lip (18) includes a cut-out (22) facing the groove (17), such that a cut-out depth (23) measured between the upper plane (48) and a lowest point (24) of the cut-out (22) is greater than a vertical height (32) of the male part (29) measured between a lowest point (32) of the male part (29) and the upper side (13) of the panel (10); and/or the tongue (16) further includes a cut-out (35) facing the recess (25), such that a vertical height (36) of the cut-out (35) measured between the upper side (13) of the panel (10) and an uppermost point (46) of the cut-out (35) is less than a vertical height (34) of the female part (28) measured between an uppermost point (37) of the female part (28) and the upper plane (48).

32. The method according to claim 31, wherein a difference between the groove depth (20) and the vertical height (32) of the male part (29) is less than 1 mm.

33. The method according to any of the preceding claims 31 to 32, wherein the depth (23) of the lower cut-out (22) is greater than the vertical height (32) of the male part (29) by at least 0.1 mm.

34. The method according to any of the preceding claims 31 to 33, wherein the lower cutout (22) does not participate in a coupling of the first pair of opposite edges (14, 15).

35. The method according to any of the preceding claims 31 to 34, wherein a difference between the recess depth (26) and the vertical height (34) of the female part (28) is less than 1 mm.

36. The method according to any of the preceding claims 31 to 35, wherein the vertical height (36) of the upper cut-out (35) is less than the vertical height (34) of the female part (28) by at least 0.1 mm.

37. The method according to any of the preceding claims 31 to 36, wherein the upper cutout (35) does not participate in a coupling of the first pair of opposite edges (14, 15).

38. The method according to any of the preceding claims 31 to 37, wherein a width of the upper cut-out (35) is less than 0.5 mm, preferably less than 0.3 mm.

39. The method according to any of the preceding claims 31 to 38, wherein a width of the lower cut-out (22) is less than 0.5 mm, preferably less than 0.3 mm.

40. The method according to any of the preceding claims 31 to 39, wherein the male coupling part (29) and the female coupling part (28) of the second pair of opposite edges (56, 57) comprise a tongue and a groove, respectively.

41. A method for manufacturing a panel (10), the method comprising: advancing a panel (10) relative to a first milling device having at least two milling tools, the panel (10) having an upper side (13) defining an upper plane (48); treating a first pair of opposite edges (14 ,15) of the panel (10) by means of the at least two milling tools of the first milling device to form coupling parts in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being bordered by an upper lip (19) and a lower lip (18); advancing the panel (10) relative to a second milling device having at least two milling tools; treating a second pair of opposite edges (56, 57) of the panel (10) by means of the at least two milling tools of the second milling device to form coupling parts in the form of a male coupling part (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling part (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein a milling tool of the at least two milling tools of the first milling device and/or of the at least two milling tools of the second milling device is moved in a vertical direction with respect to the upper side (13) of the panel (10) during treatment of a corner region defined by an overlap of one of the first pair of opposite edges (14, 15) and one of the second pair of opposite edges (56, 57), such that a corner piece is removed or prevented.

42. The method according to claim 41, wherein a groove depth (20) measured between the upper plane (48) and a lowest point (21) of the groove (17) is less than a vertical height (32) of the male part (29) measured between a lowest point (32) of the male part (29) and the upper side (13) of the panel (10).

43. The method according to any of the preceding claims 41 to 42, wherein a difference between the groove depth (20) and the vertical height (32) of the male part (29) is less than 1 mm.

44. The method according to any of the preceding claims 41 to 43, wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); wherein a recess depth (26) measured between the upper side (13) of the panel (10) and an uppermost point of the recess (25) is greater than a vertical height (34) of the female part (28) measured between an uppermost point (37) of the female part (28) and the upper plane (48).

45. The method according to any of the preceding claims 41 to 44, wherein a difference between the recess depth (26) and the vertical height (34) of the female part (28) is less than 1 mm.

46. The method according to any of the preceding claims 31 to 45, wherein the male coupling part (29) and the female coupling part (28) of the second pair of opposite edges (56, 57) comprise a tongue and a groove, respectively.