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EP4524344A1 - Panneau de plancher avec joint, ensemble de panneau de plancher et procédé de fabrication - Google Patents

Panneau de plancher avec joint, ensemble de panneau de plancher et procédé de fabrication Download PDF

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Publication number
EP4524344A1
EP4524344A1 EP23197709.1A EP23197709A EP4524344A1 EP 4524344 A1 EP4524344 A1 EP 4524344A1 EP 23197709 A EP23197709 A EP 23197709A EP 4524344 A1 EP4524344 A1 EP 4524344A1
Authority
EP
European Patent Office
Prior art keywords
bevel
floor panel
effect
panel
joint
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP23197709.1A
Other languages
German (de)
English (en)
Other versions
EP4524344B1 (fr
Inventor
Frank Oldorff
Sebastian Dicke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Swiss Krono Tec AG
Original Assignee
Swiss Krono Tec AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Swiss Krono Tec AG filed Critical Swiss Krono Tec AG
Priority to EP23197709.1A priority Critical patent/EP4524344B1/fr
Priority to PCT/EP2024/075627 priority patent/WO2025056746A1/fr
Publication of EP4524344A1 publication Critical patent/EP4524344A1/fr
Application granted granted Critical
Publication of EP4524344B1 publication Critical patent/EP4524344B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02005—Construction of joints, e.g. dividing strips
    • E04F15/02033—Joints with beveled or recessed upper edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02161—Floor elements with grooved main surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Definitions

  • the invention relates to a floor panel with at least one bevel, a floor panel arrangement, and a method for producing such a floor panel.
  • Floor panels such as laminate, are a popular flooring option that consists of individual panels, each made from multiple layers.
  • fiberboard is used, with additional layers on the top and bottom surfaces.
  • These layers can be made from paper, for example, which is often soaked and impregnated with special resins.
  • These layers typically include an overlay on the top for added durability, a decorative paper for visual impact, and a top layer to withstand wear and tear.
  • a counterbalance and, if necessary, an underlay for impact sound insulation are usually added to the bottom.
  • the EP 3 578 383 B1 discloses a method for finishing a prepared board.
  • a decorative paper is applied to the top side, followed by an overlay paper as an abrasion-resistant layer.
  • a countercoat is applied to the underside. When the layers are pressed together, a relief is pressed in, which can correspond to a bevel.
  • a bevel is a chamfer that is usually arranged at the edge of a floor panel, so that when two floor panels are placed together, a complete joint is created by two bevels arranged at the edge of the floor panels.
  • the EP2774770B1 discloses methods for printing a wood-based panel with a decorative layer by means of a digital printing process using various layers of lacquer and/or resin as well as a protective layer.
  • the PCT/EP2017/060710 describes a method for producing an abrasion-resistant wood-based panel with a decorative layer and an overlay comprising several resin layers with abrasion-resistant particles and the pressing of the layer structure.
  • the decors are printed digitally or analogically onto paper webs or board-shaped cores.
  • the paper webs are typically impregnated, and the impregnated materials are pressed with an AC4/AC5 paper overlay in short-cycle presses.
  • board cores are also pressed in short-cycle presses.
  • Some press plates contain elements that become visible as joints between the floor panel joints after further processing. The joint edges are milled in a process. The milled bevels are then painted over. Various colors are selected to match the decors.
  • the invention is based on the technical problem of visually designing the bevel on a floor panel in such a way that it appears deeper while simultaneously remaining protected by an overlay. At the same time, in an arrangement of multiple floor panels, the joints resulting from two adjacent bevels at the edges of the floor panels should appear deeper.
  • One aspect of the invention relates to a floor panel with at least part of a bevel, wherein the floor panel comprises a plate-shaped core with a visible printed layer, an overlay on the visible printed layer such that the visible printed layer is protected by the overlay and at least one bevel which is pressed into the plate-shaped core by the overlay, wherein the visible printed layer on a surface of the at least one bevel has an effect for enhancing an optical depth effect of the bevel.
  • the floor panel can be a floor slab, a panel, a ceiling panel, or a wall panel.
  • the bevel can be any portion of a joint if it is divided along its width. In particular, the bevel can, for example, comprise half of the joint along its width. The width is the side along which the bevel has a chamfer in cross-section.
  • the bevel can be a straight bevel, e.g., corresponding to half of a V.
  • the bevel can have any angle, e.g., an angle between 30° and 60° to the ground plumb line.
  • the bevel can be a bevel with a shape such as a half U or a quarter circle, or have other shapes.
  • the bevel can comprise portions other than half of the complete joint, e.g., one-third or two-thirds of a V, U, semicircle, etc.
  • the slab core has the shape of a slab and is, for example, cuboid or approximately cuboid. The corners of the cuboid shape can be rounded.
  • the slab core has a length, width, and height. The length of the slab core is greater than the width and height.
  • the slab core is suitable for forming a floor panel with additional layers.
  • the visible print layer is applied to the top side of the plate-shaped core.
  • the print layer is visible in the floor panel when viewed from above.
  • the top side is the side that the floor panel will be exposed to when used. is visible as a floor covering and on which, for example, furniture can be placed and which can be walked on.
  • the floor panel also features an overlay that is applied to the print layer and at least partially covers it. This makes the print layer less susceptible to damage from mechanical impact, such as walking on the floor panel or placing objects on it, and thus more durable and resistant.
  • the overlay can be applied directly to the print layer.
  • the overlay can be transparent. The print layer is visible through the overlay.
  • the overlay can be a paper layer impregnated with resin and provided with abrasion-resistant particles. Alternatively, the overlay can be a liquid overlay.
  • the printed layer has an effect for enhancing the optical depth of the bevel on one surface of the bevel.
  • the bevel surface is the area of the upper surface of the printed layer that has a bevel in cross-section.
  • the effect is printed where the bevel is pressed in.
  • the effect is designed to make the bevel appear deeper.
  • the effect can, for example, be a 3D effect.
  • the effect for enhancing the optical depth of the bevel is designed to achieve a three-dimensional effect that is visually perceptible to humans.
  • the bevel is pressed into the floor panel with an offset.
  • the floor panel designed in this way offers the advantage that the depth-enhancing effect of the bevel makes it appear deeper than if the bevel were pressed alone. Another advantage is that the surface quality as well as the durability and longevity of the bevel are improved by the overlay placed over the printed layer, compared to the conventional process, which would require milling out the edge of the bevel to apply paint.
  • the panel-shaped core can be made of, for example, a fiberboard, plastic, solid wood, stone, concrete, metal, or other materials.
  • the panel-shaped core can be made of high-density fiberboard (HDF).
  • HDF high-density fiberboard
  • the panel-shaped core can have a height of 6 mm - 12 mm. Possible values for the length and width can be, for example, 2800 mm x 2070 mm. The size is not to be understood as limiting.
  • An exemplary floor panel comprises a fiberboard, on the upper side of which a carrier material such as a paper web is arranged.
  • the printing layer is arranged on the upper side of the carrier material and has an effect on the optical depth of the bevel in one area, for example at the edge of the panel or in the middle of the panel.
  • An overlay is arranged on the upper side of the printing layer to protect the printing layer.
  • the floor panel has a second area in which the bevel is pressed in.
  • the layers just mentioned can, for example, For example, they can be glued and/or pressed together.
  • one or more additional layers can be applied, e.g., a counter-layer or a layer for impact sound absorption.
  • One embodiment relates to a floor panel, wherein the visible print layer is applied to a carrier material different from the plate-shaped core.
  • One embodiment relates to a floor panel in which the carrier material is a paper web.
  • the paper web can be applied to the plate-shaped core.
  • the printing layer is applied to the paper web.
  • the bevel is pressed through both the paper web and the plate-shaped core.
  • the overlay can be a liquid overlay.
  • Liquid overlays are typically used for directly decorated substrates.
  • the substrate In directly decorated substrates, the substrate itself has a decoration.
  • the liquid overlay can comprise one or more liquid resin layers.
  • at least one resin layer comprises abrasion-resistant particles.
  • paper webs can have widths of 2070 mm.
  • Possible examples of decorative paper webs can have a basis weight of 50-65 g/ m2 .
  • the paper web can be impregnated, for example, to make the colors more vibrant and/or to make the paper web less sensitive to liquids.
  • the paper web can be pressed and/or glued to the sheet-like core, for example.
  • One embodiment relates to a floor panel, wherein at least one of the at least one bevel is arranged such that it forms at least one edge of the floor panel.
  • the bevel has a long and a shorter side, as well as an offset.
  • the long side forms one edge of the floor panel.
  • the shorter side corresponds to the width of the bevel, along which the bevel has a bevel in cross-section.
  • the edge preferably extends along the width of the floor panel.
  • the edge can be arranged along the length of the floor panel.
  • One embodiment relates to a floor panel, wherein an edge opposite the edge further comprises at least one bevel.
  • the floor panel has at least two bevels, each located on a different edge of the floor panel. This has the advantage that several of these floor panels can then be placed next to one another, so that two bevels of the adjacent floor panels abut one another, thus forming a complete joint between each two adjacent floor panels.
  • One embodiment relates to a floor panel, wherein the offset of the joint is between 0.2 mm and 0.6 mm.
  • the offset refers to the difference between the surface of the panel in the area where no bevel is pressed to the deepest pressed point of the bevel.
  • One embodiment relates to a floor panel, wherein the effect comprises a color gradient.
  • the color gradient comprises various colors, hues, and/or brightnesses, wherein in particular the color, hue, and/or brightness is darkest in the center of the width and/or increases along the width with distance from the center.
  • the optical effect for enhancing the optical depth effect of the bevel comprises a color gradient from one color to another.
  • the color gradient can be formed from a darker color at the most deeply pressed point of the bevel to a lighter color at a non-pressed area.
  • the color gradient creates the visual impression that the darker areas are deeper than the lighter areas.
  • the bevel may have a color gradient from the same shade of brown as the panel to a darker shade of brown or to black at the most deeply pressed point of the bevel.
  • the color gradient are, for example, a color gradient from black to strong brown for the printing of the bevel.
  • the gradient can be structured so that black is printed at the deepest pressed point of the bevel and brown fades to the surface level.
  • markers are inserted into the print data. These can be used to align the impregnated paper sheets in the short-cycle press system and the pressed panels during sawing using cameras and a control unit. This ensures that the printed bevel is positioned precisely at the peripheral edges of the finished panel or at the positions of the pressed bevel.
  • One embodiment relates to a floor panel, wherein the floor panel has a second bevel and a third bevel, such that the second bevel and third bevel form a joint, wherein the joint is arranged within the floor panel.
  • the bevels and thus the resulting complete joint can have various cross-sectional shapes, offsets, and widths.
  • the complete joint can have a V-shaped, U-shaped, semicircular, or other cross-sectional shapes.
  • One embodiment relates to a floor panel, wherein the printed layer, in addition to the effect, has a decoration different from the effect, which is arranged outside the at least one bevel.
  • the advantage is that the floor panel can be given almost any look desired by the customer thanks to the decor.
  • the decoration is arranged in an area on top of the printed layer, with the area of the decoration being distinct from the wider area in which the effect is arranged to enhance the optical depth of the bevel.
  • Possible examples of decorations can include imitations of wood, stone, concrete, cork, or other materials, as well as combinations and variations thereof, as well as fantasy patterns.
  • a walnut decor in a dark brown tone can be used to create a particularly deep bevel as a combination of printed and pressed bevel.
  • the pressed structure for the decor can contain areas where the bevel(s) are embossed.
  • the bevel(s) can be visible on the edges of the finished panel.
  • a gradient from dark gray to black is used for the bevel area when printing the bevel.
  • an anthracite/black color gradient can be created at the positions that correspond to the bevel edge after further processing.
  • the gradient can, for example, be structured so that black is printed at the deepest point of the pressed bevel and fades to dark gray down to the surface level.
  • markings can optionally be inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling. These can be used, on the one hand, to align the impregnated paper sheets in the cutting process and also the pressed panels during sawing using cameras and a control unit. This enables the printed bevel(s) to be positioned precisely on the circumferential edges of the finished panel or at the positions of the pressed bevel.
  • the printed color gradient at the positions of the pressed bevel gives it a visually significantly deeper appearance. The contrast to the mid-gray tone is high and stands out clearly from the rest of the installed flooring surface. Without the visual enhancement provided by the printing in the area of the pressed joint, the visual effect of a deep bevel would not be possible.
  • a color gradient could be a concrete decor in a medium gray tone with a particularly deep bevel, which is realized with a combination of printed and pressed bevel.
  • a gradient from dark anthracite to black is used for the printing of the bevel.
  • an anthracite/black color gradient is created at the positions that correspond to the joint edge after further processing.
  • the gradient is structured so that black is printed at the most deeply pressed point of the bevel and then fades to brown up to the surface level.
  • markings can be inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling.
  • the bevels can also be located additionally or solely in the middle of the floor panel and not just at panel transitions. This could be the case, for example, with a panel that imitates a herringbone pattern.
  • the individual slat transitions can be printed for optical enhancement and additionally pressed as a bevel. Any color variation within the printable color space is possible in order to achieve the best possible depth impression or the desired effect. This can include, for example, solid colors, straight gradients, or even structured/speckled variants. Grids or line combinations are also conceivable to achieve specific effects. There are hardly any restrictions in this regard, especially in digital printing.
  • the printed color gradient at the positions of the pressed bevel gives it a much deeper visual appearance.
  • the contrast with the natural color of the oak is high and stands out clearly from the rest of the installed flooring. Without the visual enhancement provided by the printing in the area of the pressed bevel, this goal would not have been achievable.
  • the surface quality of the bevel is significantly better protected with the pressed bevel over the printed gradient than if the edge had to be milled out to be painted, as is the case with other common processes.
  • the print layer also includes markings or control characters, allowing the effect to be positioned precisely at the pressed bevel using an optical alignment system.
  • markings or control characters allowing the effect to be positioned precisely at the pressed bevel using an optical alignment system.
  • This offers the advantage that the positioning of the pressing equipment is simple and precise using the control characters, ensuring that the pressed joint precisely matches the optical effect of the bevel.
  • Contrasting colors are preferably used for the control characters. may include, for example, lines, dots, or combinations thereof.
  • the control characters are arranged in areas that are not visible on the finished panel, e.g., because they are cut away in a processing step.
  • the area in which the bevel is printed can correspond to the area in which the bevel is pressed.
  • the area in which the bevel is printed can protrude beyond the area in which the bevel is pressed.
  • This protrusion can have various dimensions.
  • the area of the printed bevel protrudes beyond the area of the pressed joint by the value of the tolerances of the machines used.
  • the tolerances can be 1 mm, for example. This ensures that even small deviations in the positioning of the pressed bevel compared to the printed bevel, e.g. due to inaccurate adjustment, do not result in defects. This serves quality assurance and, at the same time, low consumption of printing ink. Printing well beyond the tolerance range would also be conceivable, but would be associated with disadvantages in terms of printing ink consumption.
  • a further aspect of the invention relates to a floor panel arrangement, wherein the floor panel arrangement comprises at least two floor panels with the aforementioned features, wherein when the floor panels are joined together, the at least one bevel of a first floor panel forms a complete joint with the at least one bevel of a further floor panel.
  • the at least two floor panels can be placed next to each other, either directly or with a slight gap.
  • a panel floor covering comprises a plurality of floor panels that are placed against one another.
  • a boundary is located between adjacent panels.
  • the boundary can be a direct transition without a visible boundary, or a visible boundary, e.g., by two adjacent bevels.
  • the inventive A floor panel arrangement comprises at least two floor panels.
  • the floor panels can be the same floor panels.
  • the panels each have a bevel on at least one edge. In an arrangement of two floor panels, a complete joint is created when the panels are placed together with the bevels facing each other.
  • the panels can be placed together along the length of the panel in addition to being joined at the bevels. There is not necessarily a bevel along the length of the panels.
  • an arrangement of a large number of panels can form a continuous floor covering. This floor covering has joints formed by two bevels placed next to each other if there are a large number of boundaries between the individual panels, and has no joints if there are another large number of boundaries between the individual panels.
  • the arrangement of at least two floor panels results in a complete joint at the interface between each two panels when they are placed beveled against each other.
  • the depth of the complete joint appears significantly deeper due to the optical depth enhancement effect of the bevel, which is arranged at the edges of the adjacent panels.
  • the bevels can be printed onto the print layer and pressed into the floor panel so that the bevel is formed so that half of the joint is located on one panel and the other half on the adjacent panel.
  • Other divisions are also conceivable, e.g., 1/3 and 2/3, or the joint is completely or almost completely (e.g., > 90%) located on one of the two panels, while the adjacent panel has no or almost no joint (e.g., ⁇ 10%).
  • An arrangement of a plurality of floor panels can, for example, be arranged such that bevels are located along the width direction of the individual panels, each of which is formed by placing the bevels together at the edges of the individual panels.
  • bevels are located along the width direction of the individual panels, each of which is formed by placing the bevels together at the edges of the individual panels.
  • two opposite edges of a panel each have a bevel, so that a complete joint is created at the boundary between two panels by placing them together.
  • the joint has a V-shape
  • the bevel of one Panels have the right half of a V at one edge when the V is split with a vertical cut, e.g.
  • the opposite edge of the panel having a bevel corresponding to the left half of a V, with the deepest point of the bevel's indentation preferably being located at the boundary between the two panels.
  • the darkest shade of the effect is preferably located at the point on the panel that is indented the most, to enhance the optical depth effect of a bevel.
  • a further aspect of the invention relates to a method for producing a floor panel with at least one bevel, wherein the method comprises providing a plate-shaped core with a visible printed layer and an overlay on the visible printed layer, such that the visible printed layer is protected by the overlay. Furthermore, the method comprises pressing at least one bevel, wherein the printed layer on a surface of the at least one bevel has an effect for enhancing an optical depth effect of the bevel.
  • the overlay is applied to the print layer so that the overlay at least partially covers the print layer.
  • the overlay can be a paper layer impregnated with resin and provided with abrasion-resistant particles.
  • the overlay can be applied by pulling the overlay from a pallet onto a stack of countersheet, decorative paper and overlay in front of the short-cycle press, placing it on top and then pressing the stack into a laminate.
  • the overlay can be a liquid overlay.
  • the liquid overlay can comprise one or more liquid resin layers.
  • abrasion-resistant particles are sprinkled onto at least one resin layer. If there are multiple resin layers, intermediate drying can take place. During intermediate drying, the resin layer is only dried and thus retains a large part of its reactivity, which is utilized under the influence of pressure and temperature in the short-cycle press.
  • the method may further comprise providing a carrier material.
  • the carrier material may be a paper web.
  • the carrier material may have a decoration.
  • the carrier material may be arranged between the plate-shaped core and the printing layer.
  • Possible printing methods include digital or analog printing.
  • a digital printing system can print the decorations and the optical effect to enhance the depth of the bevel in the same step.
  • one or more printing rollers can be used, e.g., using the indirect gravure printing method on a plate.
  • An exemplary system for producing the floor panels according to the invention includes, for example, an automated panel loading system, priming and drying units, an inline primer, an analogue printing system with printing rollers or a digital printing system, a cooling device, and a stacking system.
  • the creation and preparation of the print data can be carried out, for example, in prepress using an image processing program.
  • the layers can be bonded together, for example, by gluing and/or pressing. If pressing is used, the pressing of the joint part into the panel can be performed in a separate step from the pressing of the layers, or in the same step.
  • the process steps can be integrated into common floor panel manufacturing processes without having to completely rebuild the entire production line. This makes it possible to produce floor panels with visually deeper bevels cost-effectively and thus competitively.
  • An example relates to a method for producing a floor panel, wherein the step of applying also comprises applying a decoration which is different from the effect and is arranged outside the surface of the at least one bevel.
  • the bevel printing can be performed simultaneously with the decorative printing step, allowing it to be cost-effectively integrated into existing production processes. This makes the process ideal for large-scale producers.
  • Floor panel manufacturers are generally geared toward mass production, and additional work steps or modifications to large-scale systems are always associated with significant effort and expense.
  • the effect of the bevel can be incorporated into the digital print data to enhance the optical depth effect.
  • Another example relates to a method for producing a floor panel, wherein the step of applying the effect occurs before the step of applying the overlay and wherein the step of pressing occurs after the step of applying the overlay.
  • Another example relates to a method for producing a floor panel, wherein the step of applying the printing layer, when a carrier material in the form of a paper web is used, comprises applying the printing layer beyond the plate-shaped core, wherein the paper web is pressed to the plate-shaped core.
  • the print layer is applied in an area that extends beyond the area in which the print layer is visible in the finished panel. For example, the part of the print layer that extends beyond this area is cut or sawn away in a later process step.
  • the advantage is that even minor deviations from the planned dimensions and positioning of the print layer or the other layers of the panel do not result in defects. This allows for some tolerance.
  • the print layer can be printed 1 mm beyond the area of the planned panel dimensions, and if the area actually extends beyond this area in the finished panel, this excess area is then cut away.
  • the described components of the embodiment each represent individual, independently considered features of the invention, which also further develop the invention independently of one another and are thus also to be considered as components of the invention, either individually or in a combination other than that shown.
  • the described embodiment can also be supplemented by further features of the invention already described.
  • Fig. 1 shows a floor panel 1 in cross-section.
  • the floor panel 1 has, among other things, a plate-shaped core 20.
  • the plate-shaped core 20 can consist of wood, stone, plastic, concrete, metal or other materials, in particular it can consist of a fiberboard, for example.
  • a printing layer 40 is arranged on the upper side 22 of the plate-shaped core 20.
  • An overlay 50 is arranged on the printing layer 40.
  • the printing layer 40 contains an effect for enhancing the optical depth effect of a bevel 24.
  • the printing layer 40 can additionally have a decoration 70 and/or control characters for positioning for pressing. Further layers are optionally possible.
  • the layer thickness, which runs along the y-axis, can be freely selected within the limits specified by the material.
  • the plate-shaped core 20 can have a significantly greater layer thickness than the pressure layer 40 and the overlay 50.
  • a chamfer 24 is arranged on an edge 5 of the floor panel 1. The chamfer 24 is pressed into the panel 1 to a depth t. Possible values for t can be freely selected. Examples of the offset t are 0.2 - 0.6 mm.
  • the shape of the chamfer 24 can be, for example, V-shaped, whereby the chamfer can be, for example, half of a V or another portion of the entire V.
  • Other possible chamfer shapes can be, for example, a shape similar to a U, a rectangle, a parabola, an arc of a circle, or combinations thereof, whereby the list is not exhaustive.
  • the further edge 5, drawn with a wavy line, can optionally have, for example, a chamfer 24, or no chamfer, or a complete joint 25.
  • the floor panel 1 may optionally comprise further layers, which may be arranged on the top, bottom and/or between the above-mentioned layers. In this embodiment, however, it is provided that the Floor panel 1 has only a plate-shaped core 20, a printing layer 40 and an overlay 50.
  • FIG. 2 The cross section of another embodiment is shown, which is a variant of the Fig. 1
  • the illustrated embodiment shows Fig. 2
  • the embodiment shown differs from the variant in Fig. 1 in that the floor panel 1 additionally comprises a carrier material 30.
  • the carrier material 30 is arranged on the upper side 22 of the plate-shaped core.
  • the carrier material 30 can be, for example, a paper web.
  • the printing layer 40 is applied to a first side 32 of the carrier material 30.
  • the first side 32 is the upper side, i.e., the side of the carrier material opposite the plate-shaped core.
  • FIG. 3 The cross section of another embodiment is shown, which is a variant of the Fig. 1
  • the illustrated embodiment shows Fig. 3
  • the embodiment shown differs from the variant in Fig. 1 in that a complete joint 25 is arranged at the edge 5 of the panel 1, while in the variant in Fig. 1 a bevel 24 is arranged at the edge 5 of the panel.
  • the complete joint 25 shown has, as an example, the shape of a V.
  • Other shapes of the joint 25, such as a U, a circular arc, a rectangle, and others, are possible.
  • the Fig. 4 The embodiment shown in cross section is a variant of the Fig. 1 illustrated embodiment and differs in that a second joint 60 is arranged in the middle of the floor panel 1.
  • Chamfers 24 or even complete joints 25 can also be arranged on the two edges 5 of the floor panel 1.
  • Fig. 5 shows a floor panel arrangement 100 consisting of two adjacent floor panels 1 in cross section.
  • the floor panels 1 in this example are like the panel 1 in Fig. 1
  • the panels 1 can be designed as shown in Fig. 2 , 3 or 4 or have other variants.
  • the two panels 1 can be placed next to each other such that the two bevels 24 at the edge 5 of the panels 1 together form a complete joint 25.
  • the shape of the joint 25 or the bevels 24 may be V-shaped in cross-section. Other possible embodiments may have differently shaped bevels 24 or joints 25.
  • FIG. 6 A plan view of two adjacent floor panels 1 is shown.
  • the floor panels 1 can have cross sections such as those shown in Fig. 1-4 shown floor panels 1.
  • the cross sections of the adjacent floor panels 1 can be as shown in Fig. 5 shown.
  • Other cross sections are also possible.
  • a bevel 24 is arranged on the edge 5 of each of the two floor panels 1.
  • the two floor panels 1 are placed against one another in such a way that the two bevels 24 together form a complete joint 25.
  • the surface of the bevel 24 on the edge 5 of the floor panels 1 is printed with an optical effect to enhance the depth effect of the bevel 24.
  • the area of the printed bevel 24 can have the same extent in the x and/or z direction as the area in which the bevel 24 is pressed.
  • the area of the printed bevel 24 can extend beyond the area of the pressed bevel 24 in the x and/or z direction.
  • the floor panel 1 can have a decor 70.
  • the decor 70 can be designed, for example, as an imitation of wood, stone, concrete, or other materials, or as any desired pattern.
  • the decors 70 of both panels 1 are identical.
  • the panels 1 can have different decors 70.
  • An exemplary method for producing a floor panel 1 with a bevel 24 comprises providing a plate-shaped core 20 with a visible printing layer 40 and an overlay 50 on the visible printing layer 40, such that the visible printing layer 40 is protected by the overlay 50.
  • the method further comprises pressing the bevel 24, such that a bevel is formed in the cross-section of the floor panel in the region of the bevel 24.
  • the printing layer 40 comprises an effect to enhance the depth effect of a chamfer 24.
  • the method may further comprise coating the printing layer 40 with an overlay 50.
  • the panel-shaped core 20 can, for example, be a fiberboard or consist of solid wood, other composite wood, plastic, concrete, stone, or metal, or combinations thereof, the list being non-exhaustive.
  • the printing layer 40 can be applied, for example, using a digital printing process or analog printing.
  • the printing data can be processed and/or created.
  • the printing data includes data for printing the effect to enhance the optical impact of the bevel 24.
  • the printing data can also contain data for printing a decoration 70.
  • the printing data can also contain data for printing control characters or markings.
  • the control characters or markings are designed to serve to align the machines with which the joint is pressed into the panel.
  • the printing rollers can be manufactured in a prior step. The printing rollers are manufactured in such a way that they are aligned to print the effect to enhance the optical impact of the bevel 24 onto the printing layer 40.
  • the printing rollers can also be configured to print a decoration 70 and/or control characters or markings.
  • the method may include a step of pressing the carrier material 30 to the plate-shaped core 20.
  • the method may include a step of bonding the carrier material 30 to the plate-shaped core 20.
  • the method may include a step of pressing and/or bonding the overlay 50 to the printing layer 40. If a pressing step is used, it may be performed separately from the step of pressing the bevel 24 into the panel 1 or simultaneously therewith.
  • An exemplary method for producing a floor panel 1 with a bevel 24 comprises: providing a plate-shaped core 20, e.g. in the form of a fiberboard, and a carrier material 30, e.g. in the form of a paper web; optionally impregnating the paper web, e.g. with a resin; subsequently bonding the carrier material 30 to the plate-shaped core 20; subsequently printing the provided print data is applied to the carrier material 30 using a digital printing process, wherein the print data comprises a decoration 70, control characters for positioning the presses, and an optical effect for enhancing the optical depth effect of the bevel 24, which can be, for example, a color gradient from brown to black.
  • the decoration 70 can, for example, be a wood decoration; other examples are imitations of cork, concrete, stone, fantasy decorations, or any desired pattern.
  • an overlay 50 is applied thereto, for example by gluing.
  • the overlay 50 protects the print layer 40 from scratching, abrasion, and other mechanical influences and is preferably liquid-repellent.
  • a bevel 24 is then pressed into the panel 1, wherein the area into which the bevel 24 is pressed at least partially overlaps the area in which the effect for enhancing the optical depth effect of the bevel 24 is printed.
  • the bevel 24 can have a V-shape and be pressed onto a panel 1.
  • the deepest point along the press-in depth t of the pressed-in bevel 24 corresponds to the darkest shade of the printed effect to enhance the optical depth effect of the bevel 24.
  • it is possible to insert further layers and steps into this process e.g., applying a layer to the plate-shaped core 10 on the underside, i.e., on the side opposite the printed layer 40. Further layers between the other layers are optionally possible.
  • the effect of the chamfer appearing deeper can be achieved by printing a three-dimensional effect to enhance the optical depth effect of a chamfer exactly in the area where the pressed chamfer 24 is located.
  • the effect of enhancing the optical depth of a bevel 24 can be adjusted in various ways to the decor 70 or its color scheme to achieve the desired degree of visual depth.
  • the printing of the bevel 24 takes place simultaneously with the decor printing step and can thus be cost-effectively integrated into existing production processes. This makes the process very suitable for large-scale producers. Manufacturers of floor panels are generally geared towards mass production and additional Work steps or modifications to large-scale systems always involve high effort and costs.
  • the bevels 24 can be inserted into the digital print data.
  • information for the joints for engraving the printing rollers is included in the separation data.
  • the effects/colors/contrast levels/gradients can be created in image processing programs.
  • precise positioning is necessary in order to precisely match the area of the pressed bevel 24 and the area of the effect for enhancing the optical depth effect of the bevel 24 in the print layer 40 during further processing.
  • such an effect for enhancing the optical depth effect of a bevel 24 can be implemented quite easily even for existing decorations 70, since only the data is changed.
  • new rollers must also be engraved in which the effect for enhancing the optical depth effect of a bevel 24 is included as a printing element.
  • a first exemplary possibility is that the effect for enhancing the optical depth effect of a chamfer 24 is only printed in the exact area which, after further processing, corresponds to the area of the pressed chamfer 24.
  • the entire areas in the print between the panel transitions are printed with the effect for enhancing the optical depth of a bevel 24. This means that the areas that are sawn away or profiled in further processing steps are also printed. This will not be visible in the final format. This consumes a particularly large amount of ink, which could lead to unfavorable costs.
  • Control characters in contrasting colors can also be printed to align finishing equipment. These can be lines, dots, or similar. The goal is to position the areas of the printed effects to enhance the optical depth effect of a chamfer 24 with the help of optical alignment equipment so that they correspond exactly to the area in which the chamfer 24 is pressed.
  • control characters can also be used for alignment when sawing the panels.
  • the joint elements can also be located additionally or solely in the middle of the floor panel and not just at panel transitions. This can be the case, for example, with a panel that imitates a herringbone pattern.
  • the individual edges 5 of the panels 1 or the individual areas of the pressed bevel 24 can be printed with an effect to enhance the optical depth effect of a bevel 24, and a bevel 24 can also be pressed.
  • a manufacturer of laminate flooring uses an industrial digital printer to print wood, stone, and fantasy decors onto decorative paper sheets.
  • the paper sheet is up to 2070 mm wide and has a basis weight of 50-65 g/m 2 .
  • Paper is primed inline at 3-6 g/ m2 .
  • the printing system can produce 50 million m2 and more of decorative paper per year.
  • the creation and preparation of the print data takes place in prepress using image editing programs.
  • the manufacturer's sales department/customer requests an oak decor in a natural shade with a particularly strong bevel 24, or, when placed side by side to form a complete joint 25, with a particularly strong joint 25. This is to be achieved using a combination of printed and pressed bevel 24.
  • the press structure for the decor contains areas in which the bevels are pressed so that the joints at the edges 5 of the finished panel 1 become visible.
  • a gradient from black to strong brown is desired.
  • the gradient is structured so that black is printed at the deepest point of the pressed bevel 24 along the offset t and brown fades to the surface level.
  • markings are inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling.
  • the surface quality of the chamfer 24 is with the pressed chamfer 24 over the printing layer 40, which has the effect of enhancing the optical depth effect of a
  • the 24-bevel and the 50-overlay above it are significantly more protected than if the edge had to be milled out and painted, as in other conventional processes. By applying this process, the optical effect could be significantly changed without compromising quality. This gives the manufacturer a significant competitive advantage, helping them sell their products more effectively on the market.
  • a manufacturer of laminate flooring uses digital printing to print wood, stone, and fantasy decors on high-density fiberboard (HDF).
  • the boards are 2800 mm long, 2070 mm wide, and 6-12 mm thick.
  • the entire system has a feed speed of 80 m/min with a board gap of approximately 1500 mm and is fully automated.
  • the system includes automated board loading, priming and drying units, an inline primer and digital printing system, a cooling device, and stacking.
  • the creation and preparation of the print data takes place in prepress using image editing programs.
  • a customer of the manufacturer requests a concrete decor in a medium gray tone with a particularly deep bevel 24. This is to be implemented using a combination of printed and pressed bevel 24.
  • the press structure for the decor 70 contains areas in which the bevels 24 are pressed, which become visible at the edges 5 of the finished panel.
  • a gradient from dark anthracite to black is used.
  • an anthracite/black color gradient is created at the positions that correspond to the panel edges 5 after further processing.
  • the gradient is structured so that black is printed at the deepest point of the pressed bevel 24 and brown fades to the surface level.
  • markings are inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling. These are used for alignment using cameras and a control unit of the impregnated paper sheets in the short-cycle press and the pressed panels during sawing.
  • the surface quality of the bevel 24 is also significantly better protected with the pressed bevel 24 over the printed layer 40, which has the effect of enhancing the optical depth effect of a bevel 24, and the overlying overlay 50, than if the edge had to be milled out in order to coat it with paint as in other conventional processes.
  • a manufacturer of laminate flooring uses digital printing to print wood, stone, and fantasy designs on high-density fiberboard (HDF).
  • the boards are 2800 mm long, 2070 mm wide, and 6-12 mm thick.
  • the entire system has a feed speed of 80 m/min with a board gap of approximately 1500 mm and is fully automated.
  • the system includes automated board loading, priming and drying units, inline primer, and analog printing system/printing rollers for indirect gravure printing on boards, a cooling system, and stacking.
  • the creation and preparation of the print data takes place in prepress using image editing programs.
  • the press structure for decor 70 contains areas in which the bevels are pressed, which become visible at edges 5 of the finished panel.
  • a gradient from dark gray to black is used.
  • an anthracite/black color gradient is created at the positions that correspond to the bevel edge after further processing.
  • the gradient is structured so that black is printed at the deepest point of the pressed bevel 24 and fades to dark gray down to the surface level.
  • markings are inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling.
  • These markings are used on the one hand to align the impregnated paper sheets in the short-cycle press and also the pressed panels during sawing using cameras and a control unit. This ensures that the printed bevel is located exactly on the peripheral edges 5 of the finished panel or in the area of the pressed bevel 24.
  • the printed color gradient in the area of the pressed bevel 24 gives it a much deeper visual appearance.
  • the contrast with the mid-gray tone is high and stands out clearly from the rest of the installed floor covering surface.
  • the surface quality of the joint is also significantly better protected with the pressed joint over the printed layer 40, which contains the effect of enhancing the optical depth of a bevel, and the overlay 50 above it, than if the edge had to be milled out in order to paint it, as in other conventional processes. By applying this process, the optical effect could be significantly changed without any loss of quality.
  • the floor panel 1 may have at least a part of a joint 25, wherein the floor panel 1 comprises: a plate-shaped core 20, a carrier material 30, a printing layer 40 applied to the carrier material 30 is applied within a first region on a first side 32 of the carrier material 30, wherein the printing layer 40 in the first region has an effect for enhancing an optical depth effect of the joint 25; an overlay 50 on the printing layer 40, so that the printing layer 40 is protected by the overlay 50; and at least a part of the at least one joint 25 in a second region, which is pressed from the first side 32 through the carrier material 30 into the plate-shaped core 20, wherein the second region is arranged within the first region, wherein the joint 25 has a width which is different from an offset t and a longer side of the joint 25.
  • the floor panel 1 may be constructed as in the first example, wherein the plate-shaped core 20 is the carrier material 30.
  • the floor panel 1 may be constructed as in the first example, wherein the carrier material 30 is a paper web.
  • the floor panel 1 may be designed as in the first, second or third example, wherein a part of the at least one joint 25 is arranged such that it forms at least one edge 5 of the floor panel 1.
  • the floor panel 1 may be as in one of the previous examples, wherein the at least part of the at least one joint 25 corresponds to one half of the joint 25 along the width of the joint 25.
  • the floor panel 1 may be designed as in one of the previous examples, wherein the joint has a V-shape along the width in cross-section.
  • the floor panel 1 may be designed as in one of the previous examples, wherein the offset t of the joint is between 0.2 mm and 0.6 mm.
  • the floor panel 1 may be as in any of the previous examples, wherein the effect comprises a color gradient along the width, wherein the color gradient changes its color and/or brightness, wherein in particular the color and/or brightness is darkest in a center of the width of the joint 25 and/or increases along the width with distance from the center.
  • the floor panel 1 may be designed as in one of the previous examples, wherein the floor panel 1 has a further second joint 25 which is different from the at least part of the at least one joint 25.
  • the floor panel 1 may be designed as in one of the previous examples, wherein the print layer 40, in addition to the effect, has a decoration 70 different from the effect, which is arranged outside the at least one joint 25.
  • a floor panel arrangement 100 may comprise at least two floor panels 1 according to one of the previous examples, wherein when a first part of the joint 25 of a first of the at least two floor panels 1 is joined to a part of the joint 25 of another of the at least two floor panels 1, the respective parts of the joint 25 form a complete joint 25.
  • a method may be as in the previous example, wherein the step of applying also comprises applying a decoration 70 which is different from the effect and is arranged outside the at least part of the at least one joint 25.
  • a method may be as in the two previous examples, wherein the step of applying the effect occurs before the step of applying the overlay 50 and wherein the step of pressing occurs after the step of applying the overlay 50.
  • a method may be as in the previous examples, wherein the step of applying the printing layer 40, when the carrier material 30 is a paper web, comprises applying the printing layer 40 beyond the plate-shaped core 20, wherein the paper web is pressed to the plate-shaped core 20.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
EP23197709.1A 2023-09-15 2023-09-15 Panneau de plancher avec joint, ensemble de panneau de plancher et procédé de fabrication Active EP4524344B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP23197709.1A EP4524344B1 (fr) 2023-09-15 2023-09-15 Panneau de plancher avec joint, ensemble de panneau de plancher et procédé de fabrication
PCT/EP2024/075627 WO2025056746A1 (fr) 2023-09-15 2024-09-13 Panneau de plancher avec joint, agencement de panneau de plancher et procédé de production

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP23197709.1A EP4524344B1 (fr) 2023-09-15 2023-09-15 Panneau de plancher avec joint, ensemble de panneau de plancher et procédé de fabrication

Publications (2)

Publication Number Publication Date
EP4524344A1 true EP4524344A1 (fr) 2025-03-19
EP4524344B1 EP4524344B1 (fr) 2025-12-17

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EP (1) EP4524344B1 (fr)
WO (1) WO2025056746A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010022535A1 (de) * 2010-05-27 2011-12-01 Pergo AG Verfahren zur Herstellung eines Oberflächenelements
EP2774770B1 (fr) 2013-03-08 2015-04-29 Flooring Technologies Ltd. Procédé d'impression d'une plaque en matériau dérivé du bois et plaque en matériau dérivé du bois dotée d'une couche décorative imprimée
EP3578383B1 (fr) 2018-06-08 2023-06-07 Flooring Technologies Ltd. Procédé de finissage d'un panneau de construction

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN120359339A (zh) * 2022-12-16 2025-07-22 利格纳姆技术股份公司 装饰面板

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010022535A1 (de) * 2010-05-27 2011-12-01 Pergo AG Verfahren zur Herstellung eines Oberflächenelements
EP2774770B1 (fr) 2013-03-08 2015-04-29 Flooring Technologies Ltd. Procédé d'impression d'une plaque en matériau dérivé du bois et plaque en matériau dérivé du bois dotée d'une couche décorative imprimée
EP3578383B1 (fr) 2018-06-08 2023-06-07 Flooring Technologies Ltd. Procédé de finissage d'un panneau de construction

Also Published As

Publication number Publication date
EP4524344B1 (fr) 2025-12-17
WO2025056746A1 (fr) 2025-03-20

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