Method for producing panel having embossed structure

Abstract

The present disclosure relates to a method of producing a panel having an embossed structure, comprising: forming a substrate (10; 10 '), wherein the substrate (10; 10 ') comprises a polymer-based material; providing a printed polymer base film (1); the printed polymer base film (1) is applied to the substrate (10; 10 '), the printed polymer base film (1) being continuously applied to the substrate (10; 10 '); the printed polymer base film (1) is pressed onto the substrate (10; the invention relates to a method for manufacturing a laminated panel (10, 10 '), whereby a laminated substrate (20) is formed, and embossing the laminated substrate (20) by means of an embossing device (31, 33) having a circumference (C2) such that the laminated substrate (20) obtains an embossed structure, dividing the laminated substrate into a plurality of panels, each panel having a length (L2) and a width (W2), where the circumference (C2) of the embossing device (31, 33) divided by the length (L2) of the panel is a non-integer.

Description

Technical Field

[0001] Examples of the present disclosure relate to a method of producing a panel having an embossed structure. The panel may be a building panel such as a floor panel, a furniture component, a worktop, a wall panel, a ceiling panel. Background Art

[0002] Panels such as architectural panels may have prints for decorative purposes. The print may be a wood grain pattern that simulates wood. In other examples, the print may be a stone pattern that simulates stone, or a fantasy pattern. To increase the realism of the panel, the panel may have an embossed structure, including embossed portions and protrusions. The embossed structure may be aligned with the print so that the embossed structure matches elements of the print. Elements of the print may be wood grain, knots, medullary rays, and other elements that depict the structure of the wood.

[0003] Prints can be printed using various methods. One common method is rotogravure printing, where the pattern is printed by several gravure cylinders. Digital printing allows for more variations in prints and is therefore more flexible than engraving gravure cylinders.

[0004] Vinyl tiles have become increasingly successful in the flooring sector in recent years. One type of tile is SPC (Stone Plastic Composite), where the core is formed by extruding a core material in a continuous process. The pattern is provided by a separate printed film, most commonly printed by rotogravure. The printed film and a protective layer arranged over the printed film are pressed onto the core by one or more pressing rollers. An embossing roller can press the embossed structure into the panel.

[0005] Due to the cost of engraved gravure cylinders and embossing rollers, the number of unique designs is limited. Therefore, after the substrate is divided into individual panels, a certain repetition of the pattern occurs after a certain number of panels. Such repetition is undesirable when installing the floor. Therefore, it is desirable to increase the number of variations and reduce the number of identical panels to improve the realistic look of the floor. Summary of the invention

[0006] It is an object of at least some examples of the present disclosure to provide improvements over the above-described techniques and known techniques.

[0007] According to a first aspect of the present disclosure, there is provided a method for producing a panel having an embossed structure. The method comprises:

[0008] providing a substrate, wherein the substrate comprises a polymer-based material (i.e., a polymer-based material),

[0009] providing a printed polymer-based film (i.e., a polymer-based film),

[0010] Apply the printed polymer base film to the substrate,

[0011] pressing the printed polymer base film onto a substrate to form a laminated substrate, and

[0012] The laminated substrate is embossed by an embossing device having a certain circumference so that the laminated substrate obtains an embossed structure,

[0013] dividing the laminate substrate into a plurality of panels, each panel having a certain length and width, and

[0014] The circumference of the embossing device divided by the length of the panel is a non-integer.

[0015] As used herein, the term "perimeter" refers to the length of the outer edge of a shape. Specifically, as used herein, the perimeter of an embossing device refers to the length of the outer edge of the embossing device, which corresponds to the embossing length, such as the length of the embossed structure.

[0016] Providing the substrate may include forming the substrate by a continuous process.

[0017] The printed polymer base film may be applied continuously to a substrate.

[0018] Since the length of the panels does not correspond to the circumference of the embossing device and thus to the length of the embossed structure, there is a displacement of the embossed structure between the individual panels. As a result, the embossed structure of one panel is different from the embossed structure of another panel. As a result, the number of different panels obtained can be increased.

[0019] "Non-integer" can be thought of as a shift factor.

[0020] The laminate substrate may be divided into multiple panels of equal length.

[0021] The substrate may have a certain length and width. The printed polymer base film may have a certain length and width. The length direction of the printed polymer base film may be substantially parallel to the length direction of the substrate.

[0022] The embossed structure may have a length and a width, wherein the length direction of the embossed structure may be substantially parallel to the length direction of the printed polymer base film.

[0023] The embossing device can be an embossing roller or an embossing belt.

[0024] Pressing and embossing may be performed simultaneously. Pressing and embossing may be performed by a common device, such as an embossing roller or an embossing belt configured for both pressing and embossing.

[0025] The circumference of the embossing device may be greater than the length of the panel.

[0026] The circumference of the embossing device may be at least 110% of the length of the panel.

[0027] The circumference of the embossing device may be in the range of 110-190% of the length of the panel.

[0028] The non-integer may be greater than 1.

[0029] The non-integer may be in the range of 1.1-1.9. The non-integer may be in the range of 2.1-2.9. The non-integer may be in the range of integer n+0.1 to integer n+0.9, for example, in the range of 1.1-1.9 or 2.1-2.9 or 3.1-3.9. The selection of integers should avoid unnecessary repetition, for example, avoid integers equal to n+0.5, such as 1.5, 2.5, etc. Thus, the non-integer may be in the range of integers n+0.1 to n+0.4 and n+0.6 to n+0.9; for example, 1.1-1.4, 1.6-1.9, 2.1-2.4, 2.6-2.9, 3.1-3.4, 3.6-3.9, etc.

[0030] The embossed structure can be aligned at least partially with the pattern of the printed polymer base film. Generally, the pattern of the polymer base film contains a large number of design elements. The embossed structure corresponding to the pattern of the polymer base film usually contains a part of the design elements. If the pattern of the polymer base film is complex or crowded, the complete embossing aligned with this pattern may have an unfavorable appearance. As used herein, the expression "aligned with the pattern portion" refers to alignment with a part of the pattern. Therefore, the embossed structure can be aligned with at least a part of the pattern of the printed polymer base film.

[0031] The pattern may have a pattern repeat having a pattern repeat length, wherein the circumference of the embossing device may substantially correspond to the pattern repeat length.

[0032] A pattern repeat may include one or more patterns, wherein each pattern is different from other patterns in the pattern repeat.

[0033] The repeat length can be measured along the length of the printed polymer base film.

[0034] The pattern repeat length may be measured from the start point of the first pattern in the pattern repeat portion to the end point of the last pattern in the pattern repeat portion, and is measured in the length direction of the polymer base film. In the case where the pattern repeat portion includes only one pattern, the pattern repeat length may be measured from the start point of the pattern to the end point of the pattern, and is measured in the length direction of the polymer base film.

[0035] The printed polymeric base film may be printed by means of a rotogravure cylinder, wherein the circumference of the rotogravure cylinder may substantially correspond to the circumference of the embossing device.

[0036] The polymer-based film may be printed by digital printing, such as inkjet printing.

[0037] The panels may be planks or tiles.

[0038] The one or more patterns may be one or more wood grain patterns.

[0039] The substrate may be formed by a continuous process.

[0040] The polymer-based film may be applied continuously to the substrate.

[0041] The polymer-based film may be applied in-line during the production process of the substrate.

[0042] Forming the substrate and applying the polymer-based film may be a continuous process.

[0043] The substrate may be formed by extrusion.

[0044] The barrel temperature of the extruder can be 145-225°C.

[0045] The polymer-based film may be applied to the substrate prior to cooling the substrate.

[0046] The polymer of the polymer base film may be a thermoplastic polymer.

[0047] The polymer of the polymer-based film may be a thermosetting polymer.

[0048] The polymer-based film may be paper-free, for example, non-paper-based.

[0049] The polymer base film may be made of a polymer material, such as a thermoplastic or thermosetting material. The polymer base film may be a PVC film.

[0050] The polymer-based material of the substrate may be a thermoplastic material or a thermosetting material.

[0051] The substrate may further comprise a filler. The filler may be an organic and / or inorganic filler. The filler may be one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, sawdust, crushed rice husk, cork and bamboo powder.

[0052] Pressing may include applying heat and pressure.

[0053] The method may further include applying a protective layer to the polymer-based film prior to embossing.

[0054] The protective layer may be a polymer-based film, such as a thermoplastic film or a thermosetting film.

[0055] According to a second aspect, there is provided a method of producing a panel having an embossed structure. The method comprises:

[0056] providing a substrate, wherein the substrate comprises a polymer-based material,

[0057] providing a polymer base film printed with a print, the print comprising a pattern repeat portion, the pattern repeat portion comprising one or more patterns, wherein the pattern repeat portion has a pattern repeat length measured along the length direction of the polymer base film,

[0058] Applying the polymer-based film to the substrate,

[0059] pressing the polymer-based film onto a substrate to form a laminated substrate, and

[0060] The laminated substrate is embossed by an embossing device so that the laminated substrate acquires an embossed structure, the laminated substrate is divided into a plurality of panels, each panel having a certain length and width, and

[0061] The result obtained by dividing the pattern repeat length by the length of the panel is a non-integer.

[0062] Providing the substrate may include forming the substrate by a continuous process.

[0063] The printed polymer base film may be applied continuously to a substrate.

[0064] If the pattern includes two or more patterns, the patterns are continuous with each other in the length direction of the polymer base film.Each pattern in the pattern repeating portion is different from other patterns in the pattern repeating portion.

[0065] Since the panel length does not correspond to the pattern repeat length, a shift of the pattern is obtained between the individual panels. Thus, the pattern of one panel is not identical to the pattern of another panel.

[0066] "Non-integer" can be thought of as a shift factor.

[0067] The circumference of the embossing device may correspond to the pattern repeat length.

[0068] The circumference of the embossing device divided by the length of the panel may be a non-integer.

[0069] Since the length of the panels does not correspond to the circumference of the embossing device and thus to the length of the embossed structure, a displacement of the embossed structure is obtained between the individual panels. As a result, the embossed structure of one panel is different from the embossed structure of another panel. Thus, the number of different panels obtained can be increased.

[0070] The pattern repeat length may be measured from the starting point of the first pattern in the pattern repeat portion to the end point of the last pattern in the pattern repeat portion, and is measured in the length direction of the polymer base film. In the case where the pattern repeat portion includes only one pattern, the pattern repeat length may be measured from the starting point of the pattern to the end point of the pattern, and is measured in the length direction of the polymer base film.

[0071] The pattern repeat length may substantially correspond to the length of the printed polymer film.If the pattern repeat comprises only one pattern in the length direction, the length of the pattern may substantially correspond to the length of the printed polymer film.

[0072] The laminate substrate may be cut into panels of equal length.

[0073] The substrate may have a certain length and width. The printed polymer base film may have a certain length and width. The length direction of the substrate may be substantially parallel to the length direction of the printed polymer base film.

[0074] The embossing device may be an embossing roller or an embossing belt.

[0075] Pressing and embossing may be performed simultaneously. Pressing and embossing may be performed by a common device, such as an embossing roller or an embossing belt configured for both pressing and embossing.

[0076] The pattern repeat length can be greater than the length of the panel.

[0077] The pattern repeat length may be at least 110% of the panel length, such as in the range of 110-190%.

[0078] The circumference of the embossing device may be greater than the length of the panel.

[0079] The circumference of the embossing device may be at least 110% of the length of the panel, such as in the range of 110-190%.

[0080] The non-integer may be greater than 1.

[0081] The non-integer may be in the range of 1.1-1.9. The non-integer may be in the range of 2.1-2.9. The non-integer may be in the range of integer n+0.1 to integer n+0.9, for example, in the range of 1.1-1.9 or 2.1-2.9 or 3.1-3.9. The selection of integers should avoid unnecessary repetition, for example, avoid integers equal to n+0.5, such as 1.5, 2.5, etc. Thus, the non-integer may be in the range of integers n+0.1 to n+0.4 and n+0.6 to n+0.9; for example, 1.1-1.4, 1.6-1.9, 2.1-2.4, 2.6-2.9, 3.1-3.4, 3.6-3.9, etc.

[0082] The embossed structure may be at least partially aligned with the one or more patterns.

[0083] The polymer-based film may be printed by means of a rotogravure cylinder, wherein the circumference of the rotogravure cylinder may correspond to the circumference of the embossing device.

[0084] The polymer-based film may be printed by digital printing, such as inkjet printing.

[0085] The panels may be planks or tiles.

[0086] The one or more patterns may be one or more wood grain patterns.

[0087] The substrate may be formed by a continuous process.

[0088] The polymer-based film may be applied continuously to the substrate.

[0089] The polymer-based film may be applied in-line during the production process of the substrate.

[0090] Forming the substrate and applying the polymer-based film may be a continuous process.

[0091] The substrate may be formed by extrusion.

[0092] The barrel temperature of the extruder can be 145-225°C.

[0093] The polymer-based film may be applied to the substrate prior to cooling the substrate.

[0094] The polymer of the polymer base film may be a thermoplastic polymer.

[0095] The polymer of the polymer-based film may be a thermosetting polymer.

[0096] The polymer-based film may be paper-free, for example, non-paper-based.

[0097] The polymer base film may be made of a polymer material, such as a thermoplastic or thermosetting material. The polymer base film may be a PVC film.

[0098] The polymer-based material of the substrate may be a thermoplastic material or a thermosetting material.

[0099] The substrate may further comprise a filler. The filler may be an organic and / or inorganic filler. The filler may be one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, sawdust, crushed rice husk, cork and bamboo powder.

[0100] Pressing may include applying heat and pressure.

[0101] The method may further include applying a protective layer to the polymer-based film prior to embossing.

[0102] The protective layer may be a polymer-based film, such as a thermoplastic film or a thermosetting film. BRIEF DESCRIPTION OF THE DRAWINGS

[0103] The present disclosure will be described in more detail, by way of example, with reference to the accompanying schematic drawings, which show examples of the present disclosure.

[0104] Figure 1A The rotogravure printing process of a polymer-based film is schematically shown.

[0105] Figure 1B The digital printing process of polymer-based films is schematically illustrated.

[0106] Figure 2A A portion of a printed polymer-based film is shown, comprising a first pattern.

[0107] Figure 2B A portion of a printed polymer-based film is shown, comprising a first pattern and a second pattern.

[0108] Figure 3 A process for forming a laminate substrate according to a first example is schematically illustrated.

[0109] Figure 4 A process for forming a laminate substrate according to a second example is schematically illustrated.

[0110] Figure 5 A process for forming a laminate substrate according to a third example is schematically illustrated.

[0111] Figure 6 A top view of a laminate substrate according to a first example is shown.

[0112] Figure 7 A top view of a laminate substrate according to a second example is shown.

[0113] Figure 8 A top view of a laminate substrate according to a third example is shown. DETAILED DESCRIPTION

[0114] Figure 1 schematically shows a cross-section of a rotogravure printing process. In rotogravure printing, one or more gravure cylinders apply ink to the substrate to be printed. Traditionally, one gravure cylinder applies one color. For CMYK, the rotogravure printing process includes four gravure cylinders. Figure 1A In FIG. 1 , a cross section of a gravure cylinder 2 is schematically shown.

[0115] In rotogravure printing, ink 6 is placed in an ink tray 4, and a gravure cylinder 2 is dipped into the ink tray 4 to transfer the ink 6 from the ink tray 4 to the substrate to be printed. The gravure cylinder 2 is engraved with a pattern. A doctor blade 5 removes excess ink 6 on the gravure cylinder 2 so that the ink 6 exists only in the concave portions of the engraved pattern of the gravure cylinder. The substrate passes between the gravure cylinder 2 and the impression roller 3. Thus, the ink 6 is transferred from the gravure cylinder 2 to the surface of the substrate. This process is repeated for each color applied.

[0116] In the present disclosure, the substrate to be printed may be a polymer base film 1. The polymer base film 1 may be a thermoplastic film. The polymer base film 1 may be a thermosetting film. In one example, the polymer base film 1 may not contain paper.

[0117] The polymer base film 1 may be made of a polymer material, which may be a thermoplastic or thermosetting material.

[0118] The polymer base film 1 can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0119] In one example, the polymer base film 1 is a PVC film; in another example, the polymer base film may be a thermosetting PU film.

[0120] The polymer base film 1 may have a thickness of 0.01 to 0.1 mm.

[0121] The polymer base film 1 may have a rectangular shape, for example, having a certain length and width. The length may exceed the width of the polymer base film 1.

[0122] The size of the polymer-based film 1 may substantially correspond to the size of the substrate to which the polymer-based film 1 will be applied in a subsequent step. The width of the polymer-based film 1 may be 1-1.5 m, for example 1 m or 1.3 m.

[0123] In one example, the polymer base film 1 is formed by Figure 1A The polymer base film 1 is printed by the rotary gravure printing process described in the embodiment of the present invention. The polymer base film 1 is printed by a gravure cylinder 2, and one or more patterns are engraved on the gravure cylinder 2 as viewed in the rotation direction of the gravure cylinder 2. The one or more patterns are continuous with each other as viewed in the rotation direction D of the gravure cylinder 2. In one example, a first pattern and a second pattern are engraved on the gravure cylinder 1. As viewed in the rotation direction D of the gravure cylinder 1, the second pattern follows the first pattern. Each pattern is unique and is not equal to or different from another pattern.

[0124] The gravure cylinder 2 has a circumference C1. The gravure cylinder 2 has a rotation axis that can be arranged parallel to the width direction of the polymer base film 1 to be printed. The gravure cylinder 2 can have a length extension direction parallel to the width direction of the polymer base film 1 to be printed. In an example where two separate patterns (i.e., a first pattern and a second pattern) are engraved on the gravure cylinder 2, the first half of the circumference C1 is engraved with the first pattern, and the second half of the circumference C1 is engraved with the second pattern.

[0125] Each of the one or more patterns may have the same length.

[0126] Typically, the circumference C1 of the gravure cylinder 2 is less than the length of the polymer base film 1, so that the one or more patterns are repeated on the polymer base film 1. The one or more patterns define a pattern repeating portion, which has a certain pattern repeating length. Each pattern of the pattern repeating portion is unique and is not the same or identical to other patterns of the pattern repeating portion. The pattern repeating length substantially corresponds to the circumference C1 of the gravure cylinder 2.

[0127] When the polymer base film 1 is printed, a print is provided on the polymer base film 1, and the print includes one or more patterns that are continuous with each other in the length direction of the polymer base film 1. In one example, a print is printed on the polymer base film 1, and the print includes a first pattern and a second pattern, wherein the second pattern is behind the first pattern when viewed in the length direction of the polymer base film 1.

[0128] In the above, rotogravure printing has been described with reference to one intaglio cylinder 2, but the skilled person will appreciate that the process is repeated for each colour forming the print.Each intaglio cylinder 1 in the rotogravure printing process typically has the same circumference C1.

[0129] Compared to rotogravure printing, which requires a separate engraving of the gravure cylinder 2 for each individual design, digital printing offers a more flexible printing process. An example of a digital printing method is the use of Figure 1B Inkjet printing is performed by the inkjet printer 7 schematically shown in FIG.

[0130] In one example of inkjet printing, the substrate to be printed is conveyed under a number of print bars 8a-8e. In the present disclosure, the substrate to be printed is the substrate described above with reference to Figure 1AThe polymer base film 1 described. The printing bars 8a-8e can extend transversely to the conveying direction or printing direction P. The printing bars 8a-8e can each include a certain number of inkjet print heads. The inkjet print heads eject ink droplets onto the substrate. The printing freedom of digital printing is not limited, but if an embossed structure aligned with the printing is required, the cost of engraving a large number of embossing rollers limits the design possibilities. Therefore, even with digital printing, the printing can be repeated over the length of the substrate to be printed.

[0131] In the present disclosure, the polymer base film 1 can be digitally printed with a pattern. The pattern can have a pattern repeating portion. The pattern repeating portion can include one or more patterns that are continuous with each other in the length direction of the polymer base film 1. Each pattern of the pattern repeating portion is unique and is not the same or equivalent to other patterns of the pattern repeating portion. The pattern repeating portion has a certain pattern repeating length. The pattern repeating length can be defined as the distance from the starting point of the first pattern of the pattern repeating portion to the end point of the last pattern of the pattern repeating portion in the length direction of the printed polymer base film 1. If the pattern repeating portion includes only one pattern, the pattern repeating length is measured from the starting point of the pattern to the end point of the pattern in the length direction of the printed polymer base film 1.

[0132] By digital printing, unnecessary pattern repetitions can be avoided. For example, the polymer base film 1 can be printed with a pattern, the extension of which in the length direction substantially corresponds to the length of the polymer base film 1. By digital printing, the pattern repetition portion can include a pattern, the length of which substantially corresponds to the length of the polymer base film 1.

[0133] The following description will be made by taking the pattern as a wood grain pattern as an example. However, in other examples, the pattern may also be any type of pattern, such as a stone grain pattern, a brick pattern, an imaginary pattern, etc.

[0134] Figure 2A -B shows an example of a portion of a printed polymer base film 1. The printed polymer base film 1 may be printed by a rotary gravure printing process, as described above with reference to Figure 1A Said, or may be printed by digital printing, as mentioned above with reference to Figure 1B described.

[0135] exist Figure 2A In the example shown, the polymer base film 1 is printed with a pattern, namely the first pattern 11, in the length direction of the printed polymer base film. In this example, the pattern repeating portion includes only one pattern. The pattern repeating length R corresponds to the length of the pattern in the length direction of the printed polymer base film 1.

[0136] Figure 2AThe first pattern 11 shown may include wood elements, such as wood grain, knots and / or medullary rays. The design of the wood elements may be designed to form a unique pattern.

[0137] exist Figure 2A , only a portion of the print of the polymer base film 1 is shown in the width direction of the polymer base film 1. The width of the print on the polymer base film 1 may be substantially the same as the width of the polymer base film 1. Therefore, only a portion of the first pattern 11 is shown in the width direction of the printed polymer base film 1. The first pattern 11 and the second pattern 12 may be considered to represent a set of first patterns and a set of second patterns in the width direction of the printed polymer base film 1, respectively.

[0138] The pattern 11 may be repeated in the length direction of the polymer base film 1 .

[0139] if Figure 2A The print shown is printed by rotary gravure printing, and the pattern repeat length R may substantially correspond to the circumference C1 of the gravure cylinder 2 .

[0140] If digital printing is adopted, the length of the pattern 11 may substantially correspond to the length of the polymer base film 1 .

[0141] Figure 2B A second example of a portion of a printed polymer base film 1 is shown. The printed polymer base film 1 may be printed by a rotogravure printing process, as described above with reference to Figure 1A Said, or may be printed by digital printing, as mentioned above with reference to Figure 1B described.

[0142] exist Figure 2B In the example shown, the polymer base film 1 is printed with two patterns in the length direction, namely the first pattern 11 and the second pattern 12. In other examples, the polymer base film 1 can be printed with any number of separate patterns exceeding two, such as 3-5 unique patterns, i.e., patterns that are different from each other and continuous in the length direction. Therefore, the pattern repeating portion can include one or more patterns in the length direction of the printed polymer base film 1.

[0143] exist Figure 2B , only a portion of the print of the polymer base film 1 is shown in the width direction of the polymer base film 1. The width of the print on the polymer base film 1 may be substantially the same as the width of the polymer base film 1. Therefore, only a portion of the first pattern 11 and the second pattern 12 are shown in the width direction of the printed polymer base film 1. The first pattern 11 and the second pattern 12 may be regarded as representing a group of first patterns and a group of second patterns in the width direction of the printed polymer base film 1, respectively.

[0144] Figure 2B A first pattern 11 and a second pattern 12 are shown. The first pattern 11 is different from the second pattern 12. The first pattern 11 and the second pattern 12 form a pattern repeat portion having a pattern repeat length R in the length direction of the printed polymer base film 1. The pattern repeat length R can be measured from the start point of the first pattern 11 to the end point of the second pattern 12. Each pattern in the pattern repeat portion can have the same length in the length direction of the printed polymer base film 1.

[0145] The first pattern 11 and the second pattern 12 can be formed by rotary gravure printing, as described above with reference to Figure 1A or formed by digital printing (e.g. inkjet printing), as described above with reference to Figure 1B No matter which method is used, the final printed pattern can be basically the same.

[0146] if Figure 2B The print shown is printed by rotary gravure printing, and the pattern repeat length R may substantially correspond to the circumference C1 of the gravure cylinder 2 .

[0147] Figure 2A and 2B The first pattern 11 and the second pattern 12 shown may include wood elements, such as wood grain, knots and / or medullary rays. The design of the wood elements may be designed to form a unique pattern.

[0148] Each pattern in the pattern repeat may contain a basic wood grain pattern. Wood elements may be added to the basic wood grain pattern, which are unique to each pattern in the pattern repeat. Wood elements unique to each pattern may be, for example, knots and / or medullary rays.

[0149] Each pattern in the pattern repeat may include a first set of design elements that are common to all patterns in the pattern repeat. Each pattern in the pattern repeat also includes a second set of design elements that are different for each pattern in the pattern repeat. The first set of design elements may form a basic wood pattern. The second set of design elements adds certain features, such as knots or medullary rays, to the basic wood pattern, making each pattern in the pattern repeat unique.

[0150] If the pattern repeating portion includes more than one pattern, these patterns can be configured to match each other, or at least to match the start and end points of adjacent patterns, as seen in the length direction of the printed polymer base film 1. The end point of a first pattern can be configured to match the start point of a second pattern, which is located after the first pattern in the length direction, so that a transition between one pattern and a subsequent pattern can be obtained. In this way, a less obvious boundary between adjacent patterns can be obtained.

[0151] The one or more patterns of the printed polymer base film 1 can be used to form an embossing device. The embossing device can be an embossing roller or an embossing belt, as will be referred to below. Figure 3-5 described.

[0152] The embossing device is engraved with an embossed structure, which is aligned or at least partially aligned with the one or more patterns of the printed polymer base film 1. The embossing device is engraved with an embossed structure, which is aligned with the one or more patterns of the printed polymer base film 1, or is aligned with a part of the one or more patterns.

[0153] In an example where the first pattern 11 and / or the second pattern 12 include a common wood grain pattern, the embossed structure may correspond to the common wood grain pattern. Thus, the embossed structure is aligned with the common wood grain pattern, so that the first pattern 11 and the second pattern 12 are aligned or partially aligned with the embossed structure.

[0154] In one example, the first pattern 11 and / or the second pattern 12 comprises a first set of design elements, which are common to both the first pattern 11 and the second pattern 12, and the embossed structure may correspond to the first set of design elements. Thus, the embossed structure is aligned with the first set of design elements, so that the first pattern 11 and the second pattern 12 are partially aligned with the embossed structure.

[0155] In one example, the pattern has a pattern repeat length that exceeds the perimeter of the embossing device, and one or more patterns forming the pattern repeat portion may have a first set of elements that are common and repeated within the pattern repeat portion, and a second set of elements that are not identical within the pattern repeat length. The second set of elements forms a unique design of the one or more patterns in the pattern repeat portion. The embossed structure of the embossing device may correspond to the first set of elements, for example, at least a portion of the one or more patterns is aligned with the embossed structure.

[0156] An example of a pattern having a pattern repeat length exceeding the circumference of the embossing device is a pattern whose length substantially corresponds to the length of the polymer base film 1 .

[0157] Figure 3 A continuous process for forming a laminate substrate is shown. The layers of the laminate substrate can be applied and joined in-line in the process.

[0158] exist Figure 3 In the process shown, the substrate 10 is produced in an extrusion process by an extruder 16 or a co-extruder. Thus, the substrate 10 is an extruded substrate. The substrate 10 is formed in a continuous process.

[0159] The substrate 10 may have a rectangular shape, for example, with a length greater than a width.

[0160] The substrate 10 may include a polymer-based material. The polymer-based material may be a thermoplastic or thermosetting material. The polymer-based material may be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The substrate 10 may include 10-60 wt % of the polymer material.

[0161] The substrate 10 may further include fillers. The fillers may be organic fillers and / or inorganic fillers. The organic fillers may be sawdust, crushed rice husks, cork, bamboo powder. The inorganic fillers may be calcium carbonate, chalk, limestone, talc, stone chips, fly ash. The substrate 10 may include 30-90 wt% of the fillers.

[0162] The substrate 10 may further include additives, such as impact modifiers, stabilizers, lubricants, foaming agents, and / or plasticizers. The substrate may include 0.1-20 wt % of the additives. The substrate 10 may further include pigments. The substrate may include 0.1-20 wt % of the pigments.

[0163] In one example, the substrate 10 may include 10-30 wt% PVC, 50-90 wt% chalk, and 0-20 wt% additives. Such a substrate 10 may be of the type conventionally referred to as SPC.

[0164] The feed rate for a continuous process including the extruder 16 or a co-extruder may be 0.5-12 m / min, such as 1-10 m / min or 1.5-9.0 m / min.

[0165] The barrel temperature of the extruder 16 may be 145-225° C. When extruding PVC, the barrel temperature of the extruder 16 may be 145-225° C. Alternatively or additionally, the extrudate temperature immediately after molding may be 90-280° C. When the substrate 10 includes PVC, the extrudate temperature may be 90-225° C., preferably 145-220° C.

[0166] The substrate 10 may be calendered by passing it through one or more calendering rollers 17a, 17b so that the substrate 10 obtains a desired thickness. After calendering, the thickness of the substrate 10 may be 2-10 mm. Alternatively or additionally, the substrate 10 may be pressed to a desired thickness.

[0167] The feed rate of the continuous process comprising the extruder 16 or co-extruder and the calender roll arrangement 17a, 17b may be 0.5-12 m / min, such as 1-10 m / min or 1.5-9.0 m / min.

[0168] After calendering, the substrate 10 may be fed onto a roller 32 .

[0169] After calendering, the above reference Figure 1A , 1B , 2A and 2B are applied to the first surface of the substrate 10. The polymer base film 1 can be obtained by Figure 1A The printing may be carried out by the rotary gravure printing method described above, or may be carried out by the rotary gravure printing method described above. Figure 1B Describes the digital printing method used for printing.

[0170] The printed polymer-based film 1 may be applied to the substrate 10 before the substrate 10 is cooled.

[0171] The printed polymer-based film 1 may be applied to the substrate 10 such that a length direction of the printed polymer-based film 1 is substantially parallel to a length direction of the substrate 10 .

[0172] exist Figure 3 In the embodiment of the present invention, a protective layer 18 is applied to the printed polymer base film 1. The protective layer 18 can be a protective film, such as a polymer base film. The polymer material of the protective film can be a thermoplastic or thermosetting material. The polymer base film can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0173] The thickness of the protective layer 18 may be 0.1-2 mm.

[0174] Optionally, a backing layer (not shown) may be applied to a second surface of the substrate 10 , opposite the printed polymer base film 1 .

[0175] The substrate 10, the printed polymer base film 1 and optionally the protective layer 18 and the backing layer are attached to each other by applying pressure, for example in a pressing and embossing device 30. Figure 3 In the example shown, the pressing and embossing device 30 comprises rollers 31 and 32. Heat may also be applied during pressing.

[0176] After applying pressure by rollers 31 and 32, a laminated substrate 20 is obtained. The laminated substrate 20 includes the substrate 10 and the printed polymer base film 1. The laminated substrate 20 may optionally further include a protective layer 18 and a backing layer.

[0177] In the pressing and embossing device 30, an embossed structure is imparted to the laminated base material 20 by an embossing roller 31. The embossing roller 31 is configured to emboss the laminated base material 20 with the embossed structure.

[0178] The pressing roller 32 may apply a counter pressure to the second surface of the substrate 10 opposite to the printed polymer base film 1 .

[0179] The embossing roller 31 is engraved with an embossing structure. The embossing roller 31 has a circumference C2. The embossing roller 31 has an embossing structure engraved on its circumferential surface.

[0180] The embossing roller 31 may have a rotation axis that may be arranged parallel to the width direction of the printed polymer base film 1. The embossing roller 31 may have a length extension direction that is parallel to the width direction of the printed polymer base film 1. The embossing roller 31 may have a rotation axis that is substantially transverse to the length direction of the polymer base film 1.

[0181] In the example where the polymer base film 1 has been printed by rotogravure, the circumference C2 of the embossing roller 31 may substantially correspond to the circumference C1 of the gravure cylinder 2. Thus, the embossed structure obtained by the embossing roller 31 may be aligned with the one or more patterns of the printed polymer base film 1, or at least partially aligned.

[0182] If the polymer base film 1 is printed by rotogravure printing, the embossing roller 31 may have a rotation axis substantially parallel to the rotation axis of the gravure cylinder 2 .

[0183] Regardless of the printing method used, the pattern repeat length R in the length direction of the printed polymer base film 1 can substantially correspond to the circumference C2 of the embossing roller 31. Thus, the embossed structure obtained by the embossing roller 31 can be aligned with the one or more patterns of the printed polymer base film 1, or at least partially aligned.

[0184] After embossing, an embossed laminate substrate 20 is obtained. The laminate substrate 20 can be further divided into a plurality of panels, which will be referred to as Figure 6-8 Give a description.

[0185] Figure 4 Shown with Figure 3 An example of a continuous process similar to the process of Figure 4 In the process, the arrangement of rollers and Figure 3 In all other respects, the above description of Figure 3 The public content also applies to Figure 4 In the example. Figure 4In the embodiment, after extrusion, the substrate 10 is calendered by passing the substrate 10 of the above type through one or more calendering rollers 17a, 17b so that the substrate 10 obtains the desired thickness. The substrate 10 is then fed to a roller 17c. A printed polymer base film 1 of the above type and an optional protective layer 18 are applied to the substrate 10 and fed between rollers 17c and 17d.

[0186] As described above, the substrate 10, the printed polymer base film 1 and the optional protective layer 18 and the backing layer are attached to each other by applying pressure, for example in a pressing and embossing device 30. Figure 4 In the example shown, the pressing and embossing device 30 comprises rollers 31 and 32. Heat may also be applied during pressing.

[0187] After pressure has been applied by rollers 31 and 32, a laminated substrate 20 is obtained. The laminated substrate 20 comprises the substrate 10 and the printed polymer base film 1. The laminated substrate 20 may optionally further comprise a protective layer 18 and a backing layer.

[0188] In the pressing and embossing device 30, an embossed structure is imparted to the laminated base material 20 by an embossing roller 31. The embossing roller 31 is configured to emboss the laminated base material 20 with the embossed structure.

[0189] The pressing roller 32 may apply a counter pressure on the second surface of the substrate 10 opposite to the printed polymer base film 1 .

[0190] The embossing roller 31 is engraved with an embossing structure. The embossing roller 31 has a circumference C2. The embossing roller 31 has an embossing structure engraved on its circumferential surface. The embossing roller 31 may correspond to Figure 3 The embossing roller in Figure 3 The public content also applies to Figure 4 The embossing roller in the.

[0191] Figure 5 Another example of a process for forming a laminate substrate is shown. Figure 5 In the process shown, a substrate 10' is provided. The substrate 10' may have been formed in a previous process. The substrate 10' may have been pressed, for example, by calendering a number of layers which together form the substrate 10'.

[0192] The substrate 10' may include a polymer-based material. The polymer-based material may be a thermoplastic or thermosetting material. The polymer-based material may be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The substrate 10' may include 10-60 wt% of the polymer material.

[0193] The substrate 10' may further comprise a filler. The filler may be organic and / or inorganic. The organic filler may be sawdust, crushed rice husk, cork, bamboo powder. The inorganic filler may be calcium carbonate, chalk, limestone, talc, stone chips, fly ash. The substrate 10 may comprise 30-90 wt% of the filler. The substrate 10' may comprise 30-90 wt% of the filler.

[0194] The substrate 10' may further comprise additives, such as impact modifiers, stabilizers, lubricants, foaming agents and / or plasticizers. The substrate may comprise 0.1-20 wt% of the additives. The substrate 10 may further comprise pigments. The substrate may comprise 0.1-20 wt% of the pigments.

[0195] The thickness of the substrate 10 ′ may be 2-10 mm.

[0196] In one example, the substrate 10 may include 10-30 wt% PVC, 50-90 wt% chalk, and 0-20 wt% additives. Such a substrate 10 may be of the type conventionally referred to as SPC.

[0197] The printed polymer base film 1 is applied to the first surface of the substrate 10. The polymer base film 1 can be printed by rotary gravure printing, as described above with reference to Figure 1A Alternatively, it may be printed by digital printing, as described above with reference to Figure 1B described.

[0198] The printed polymer-based film 1 may be applied to the substrate 10 ′ such that the length direction of the printed polymer-based film 1 is substantially parallel to the length direction of the substrate 10 ′.

[0199] exist Figure 5In the embodiment of the present invention, a protective layer 18 is applied to the printed polymer base film 1. The protective layer 18 can be a protective film, such as a polymer base film. The polymer material of the protective film can be a thermoplastic or thermosetting material. The polymer base film can be or include polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), thermoplastic polyurethane (PU), thermosetting polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

[0200] The thickness of the protective layer 18 may be 0.1-2 mm.

[0201] Optionally, a backing layer (not shown) may be applied to a second surface of the substrate 10 ′, opposite the printed polymer base film 1 .

[0202] The substrate 10 ′, the printed polymer base film 1 and optionally the protective layer 18 and the backing layer are attached to each other by applying pressure, for example in an embossing and pressing device 30 . Figure 5 In the example shown, the pressing device 30 comprises a double belt press 33, 34. Heat may also be applied during pressing.

[0203] The upper belt 33 of the double belt press is provided with an embossed structure, thereby forming an embossed belt, so that pressing and embossing are performed in one process step.

[0204] After passing through the pressing device 30, a laminated substrate 20 is obtained, which includes the substrate 10' and the printed polymer base film 1. The laminated substrate 20 may also selectively include a protective layer 18 and a backing layer. The laminated substrate 20 is provided with an embossed structure.

[0205] exist Figure 5 In the example shown, embossing is performed simultaneously with pressing to form the laminate substrate 20 .

[0206] The embossed structure of the upper pressing belt 33 is configured to emboss the laminate substrate 20 with the embossed structure. The uppermost layer may be a polymer base film 1 which has been printed.

[0207] The embossed pressed belt 33 forming the embossed belt has a circumference C3. The embossed pressed belt 33 is engraved with an embossed structure. The circumference C3 of the embossed pressed belt 33 forming the embossed belt is engraved with an embossed structure. The outer peripheral surface of the embossed pressed belt 33 can be defined as the surface length intended to be in contact with the uppermost layer of the laminated substrate 20.

[0208] The embossed pressed tape 33 has a lengthwise extension direction parallel to the lengthwise direction of the printed polymer base film 1 .

[0209] In the example where the polymer base film 1 has been printed by rotogravure, the circumference C3 of the embossing belt 33 substantially corresponds to the circumference C1 of the gravure cylinder 2. Thus, the embossed structure obtained by the embossing belt 33 can be aligned with the one or more patterns of the printed polymer base film 1, or at least partially aligned.

[0210] Regardless of the printing method used, the pattern repeat length R in the length direction of the printed polymer base film 1 substantially corresponds to the circumference C3 of the embossing pressing belt 33. Thus, the embossed structure obtained by the embossing roller 31 can be aligned with the one or more patterns of the printed polymer base film 1, or at least partially aligned.

[0211] After embossing, an embossed laminate substrate 20 is obtained. The laminate substrate 20 can be further divided into a plurality of panels, which will be referred to as Figure 6-8 Give a description.

[0212] After embossing, a coating (not shown) may be applied to the printed polymer film 1 or, if a protective layer 18 has already been applied, to the protective layer 18 .

[0213] Figure 6 An example of a laminated substrate 20 viewed from above after pressing and embossing is shown. The laminated substrate 20 includes a substrate 10 or a substrate 10' and a printed polymer base film 1. The laminated substrate 20 can be obtained by referring to Figure 3-5 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Figure 6 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Figure 6 In the example shown, the length L1 exceeds the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0214] The laminate substrate 20 is intended to be divided into a plurality of panels which are Figure 6 The laminate substrate 20 can be divided into a plurality of panels, for example by sawing. The panels can also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distances required to divide the laminate substrate 20 into the individual panels and / or the distances required to machine the mechanical locking system along the panel edges can be taken into account.

[0215] These panels can be tiles or laths. Figure 6 In the example shown, the panels are in the form of strips, ie the length L2 is greater than the width W2. Figure 6 In the example shown, the length direction of the strips is substantially parallel to the length direction of the laminate substrate 20. Each panel may have an equal length L2 and width W2.

[0216] exist Figure 6 In the example shown, the laminate substrate 20 is intended to be divided into 10 panels P11, P12, P13, P14, P15, P21, P22, P23, P24, P25. Figure 6 In the embodiment, the laminate substrate 20 is intended to be divided into panels arranged in a first row of panels P11, P12, P13, P14, P15 along the length direction of the laminate substrate 20, and panels arranged in a second row of panels P21, P22, P23, P24, P25 after the first row of panels.

[0217] In one example, the width of the panel may be 178 mm and the length may be 1219 mm (7 x 48”). If the substrate 10 is extruded in an extruder having a width of about 1 m, five panels having a width of 178 mm may be provided side by side in the width direction of the substrate 10, such as Figure 6 shown. Figure 6 The panels shown may be 1219 mm in length.

[0218] If an extruder having a width of about 1.3 m is used to extrude the substrate 10, 7 panels having a width of 178 mm can be provided side by side in the width direction of the substrate 10. Accordingly, such a laminated substrate can be intended to be divided into 14 panels.

[0219] In another example, the panel may be 305mm wide and 610mm long (12x24").

[0220] In other examples, the panels may be 229 mm wide and 1524 mm long (9 x 60"). In still other examples, the panels may be tiles that are 457 mm wide and 457 mm long (18 x 18").

[0221] Figure 6 The laminate substrate 20 shown has been embossed using an embossing device having a perimeter C2 that is greater than the length L2 of the panels into which the laminate substrate 20 is to be divided. Therefore, the length E of the embossed structure measured in the length direction of the laminate substrate 20 is greater than the length L2 of the panels. Figure 6 Indicated by a dash.

[0222] The length L2 of the panel (shown in dotted lines) does not coincide with the length E of the embossed structure (shown in dashed lines), as shown in FIG. Figure 6 shown.

[0223] As from Figure 6As can be seen in , the perimeter C2 of the embossing device divided by the length L2 of the panel is a non-integer n. The non-integer n may be greater than 1, such as 1.1-1.9. In other examples, the non-integer may be in the range of 2.1-2.9. More generally, the non-integer may be in the range of integer n+0.1 to integer n+0.9, such as in the range of 1.1-1.9 or 2.1-2.9 or 3.1-3.9. The integer may be selected to avoid unnecessary repetition, such as avoiding the integer being equal to n+0.5, such as 1.5, 2.5, etc. Therefore, the non-integer may be in the range of integers n+0.1 to n+0.4 and n+0.6 to n+0.9; for example, 1.1-1.4, 1.6-1.9, 2.1-2.4, 2.6-2.9, 3.1-3.4, 3.6-3.9, etc.

[0224] The circumference C2 of the embossing device may be at least 110% of the panel length L2. The circumference C2 of the embossing device may be 110 - 190% of the panel length L2.

[0225] Thus, the number of different panels obtained from each laminate substrate 20 can be increased. Since the embossed structure is displaced between the panels, the panels will look different. The embossed structure is displaced from one panel to another, seen in the length direction of the panel. The embossed structure of each panel obtained from each laminate substrate can be varied, thereby increasing the number of different panels obtained.

[0226] exist Figure 6 In the example shown, 10 panels with different embossed structures are obtained. In the known solution, only 5 panels with different embossed structures can be obtained.

[0227] In addition, in terms of the panel pattern, the number of different panels obtained from each laminate substrate 20 can also be increased. The length L2 of the panel (shown in dotted lines) can be inconsistent with the length of the pattern. The length of the pattern can be consistent with the length E of the embossed structure. Since the pattern is shifted between the panels, the panels look different. The pattern can be shifted from one panel to another panel in the length direction of the panel.

[0228] The embossed structure may be aligned with the print or at least partially aligned. If the printed polymer base film 1 is printed by rotogravure, the circumference C1 of the gravure cylinder 2 may substantially correspond to the circumference C2 of the embossing device 30. The circumference C2 of the embossing device 30 may correspond to the length E of the embossed structure of the panel. Thus, the embossed structure may be aligned with the print, or at least aligned with a portion of the print.

[0229] Regardless of the printing method, the pattern repeat length L may substantially correspond to the circumference C2 of the embossing device 30, so that the embossed structure may be aligned, or at least partially aligned, with the print.

[0230] In one example, the pattern repeat length does not correspond to the length E of the embossed structure. The polymer base film 1 may be printed with a pattern whose length substantially corresponds to the length of the polymer base film 1. The one or more patterns may include elements aligned with the embossed structure of the embossing device such that the embossed structure is partially aligned with the one or more patterns.

[0231] Figure 7 A second example of a laminated substrate 20 after pressing and embossing is shown as seen from above. The laminated substrate 20 comprises a substrate 10 or a substrate 10' and a printed polymer base film 1. The laminated substrate 20 may be referred to above with reference to Figure 3-5 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Figure 6 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Figure 6 In the example shown, the length L1 is greater than the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0232] The laminate substrate 20 is intended to be divided into a plurality of panels which are Figure 7 The laminate substrate 20 is divided into a plurality of panels, for example by sawing. The panels may also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distance required to divide the laminate substrate 20 into individual panels and / or the distance required to machine the mechanical locking system along the panel edges may be taken into account.

[0233] These panels can be tiles or laths. Figure 7 In the example shown, the panels are in the form of strips, i.e. the length L2 is greater than the width W2. Figure 7 In the example shown, the length direction of the strips is substantially parallel to the length direction of the laminate substrate 20. Each panel may have an equal length L2 and width W2.

[0234] exist Figure 7 In the example shown, the laminate substrate 20 is intended to be divided into 20 panels P11, P12, P13, P14, P15, P21, P22, P23, P24, P25, P31, P32, P33, P34, P35, P41, P42, P43, P44, P45. Figure 7In the embodiment, the laminate substrate 20 is intended to be divided into panels arranged as follows: a first row of panels including panels P11, P12, P13, P14, P15, a second row of panels including panels P21, P22, P23, P24, P25, a third row of panels including panels P31, P32, P33, P34, P35, and a fourth row of panels including panels P41, P42, P43, P44, P45. The rows of panels are arranged one after another in the length direction of the laminate substrate 20.

[0235] In one example, the width of the panel may be 178 mm and the length may be 1219 mm (7 x 48 "). If the substrate 10 is extruded in an extruder with a width of about 1 m, five panels with a width of 178 mm may be provided side by side in the width direction of the substrate 10, such as Figure 7 shown.

[0236] If an extruder having a width of about 1.3 m is used to extrude the substrate 10, 7 panels having a width of 178 mm can be provided side by side in the width direction of the substrate 10. Accordingly, such a laminated substrate can be intended to be divided into 28 panels.

[0237] In another example, the panel may be 305mm wide and 610mm long (12x24").

[0238] In other examples, the panels may be 229 mm wide and 1524 mm long (9 x 60"). In still other examples, the panels may be tiles that are 457 mm wide and 457 mm long (18 x 18").

[0239] Figure 7 The laminate substrate 20 shown has been embossed using an embossing device having a perimeter C2 that is greater than the length L2 of the panels into which the laminate substrate 20 is to be divided. Therefore, the length E of the embossed structure measured along the length of the laminate substrate 20 is greater than the length L2 of the panels. Figure 6 Indicated by a dashed line.

[0240] The length L2 of the panel (shown in dotted lines) does not coincide with the length E of the embossed structure (shown in dashed lines), as shown in FIG. Figure 7 shown.

[0241] like Figure 7As shown, the perimeter C2 of the embossing device is divided by the length L2 of the panel to obtain a non-integer n. The non-integer n can be greater than 1, for example 1.1-1.9. In other examples, the non-integer can be in the range of 2.1-2.9. More generally, the non-integer can be in the range of integer n+0.1 to integer n+0.9, for example in the range of 1.1-1.9 or 2.1-2.9 or 3.1-3.9. The integer can be selected to avoid unnecessary repetition, for example to avoid the integer being equal to n+0.5, such as 1.5, 2.5, etc. Therefore, the non-integer can be in the range of integers n+0.1 to n+0.4 and n+0.6 to n+0.9; for example 1.1-1.4, 1.6-1.9, 2.1-2.4, 2.6-2.9, 3.1-3.4, 3.6-3.9, etc.

[0242] The circumference C2 of the embossing device may be at least 110% of the panel length L2. The circumference C2 of the embossing device may be 110 - 190% of the panel length L2.

[0243] Thus, the number of different panels obtained from each laminate substrate 20 can be increased. Since the embossed structure is displaced between the panels, the panels will look different. The embossed structure is displaced from one panel to another, seen in the length direction of the panel. The embossed structure of each panel obtained from each laminate substrate can be varied, thereby increasing the number of different panels obtained.

[0244] exist Figure 7 In the example shown, 20 panels with different embossed structures are obtained. In the known solution, only 5 panels with different embossed structures can be obtained.

[0245] In addition, in terms of the panel pattern, the number of different panels obtained from each laminate substrate 20 can also be increased. The length L2 of the panel (shown in dotted lines) can be inconsistent with the length of the pattern. The length of the pattern can be consistent with the length E of the embossed structure. Since the pattern is shifted between the panels, the panels look different. The pattern can be shifted from one panel to another panel in the length direction of the panel.

[0246] The embossed structure may be aligned or at least partially aligned with the print. If the printed polymer base film 1 is printed by rotogravure, the circumference C1 of the gravure cylinder 2 may substantially correspond to the circumference C2 of the embossing device 30. The circumference C2 of the embossing device 30 may correspond to the length E of the embossed structure of the panel. Thus, the embossed structure may be aligned or at least partially aligned with the print.

[0247] Regardless of the printing method, the pattern repeat length L may substantially correspond to the circumference C2 of the embossing device 30, so that the embossed structure may be aligned, or at least partially aligned, with the print.

[0248] In one example, the pattern repeat length does not correspond to the length E of the embossed structure. The polymer base film 1 may be printed with a pattern whose length substantially corresponds to the length of the polymer base film 1. The one or more patterns may include elements aligned with the embossed structure of the embossing device such that the embossed structure is partially aligned with the one or more patterns.

[0249] Figure 8 A second example of a laminated substrate 20 after pressing and embossing is shown as seen from above. The laminated substrate 20 comprises a substrate 10 or a substrate 10' and a printed polymer base film 1. The laminated substrate 20 may be referred to above with reference to Figure 3-5 The planar extension direction of the polymer base film 1 substantially corresponds to the planar extension direction of the substrate 10. Figure 6 In the example shown, the laminate substrate 20 is rectangular in shape, having a length L1 and a width W1. Figure 6 In the example shown, the length L1 is greater than the width W1 of the laminate substrate 20. The length direction of the polymer-based film 1 is substantially parallel to the length direction of the substrate 10.

[0250] The laminate substrate 20 is intended to be divided into a plurality of panels which are Figure 8 The laminate substrate 20 is divided into a plurality of panels, for example by sawing. The panels may also be provided with a mechanical locking system. When dividing the laminate substrate into panels, the distance required to divide the laminate substrate 20 into individual panels and / or the distance required to machine the mechanical locking system along the panel edges may be taken into account.

[0251] These panels can be tiles or laths. Figure 8 In the example shown, the panels are in the shape of tiles, ie their length L2 is substantially the same as their width W2. Each panel may have equal length L2 and width W2.

[0252] exist Figure 8 In the example shown, the laminate substrate 20 is intended to be divided into 10 panels P11, P12, P21, P22, P31, P32, P41, P42, P51, P52. Figure 8In the embodiment, the laminate substrate 20 is intended to be divided into panels arranged as follows: a first row of panels including panels P11, P12, a second row of panels including panels P21, P22, P23, a third row of panels including panels P31, P32, a fourth row of panels including panels P41, P42, and a fifth row of panels including panels P51, P52. The rows of panels are arranged continuously with each other in the length direction of the laminate substrate 20.

[0253] In one example, the panels may be tiles with a width and length of 457 mm (18 x 18").

[0254] Figure 8 The laminate substrate 20 shown has been embossed using an embossing device having a perimeter C2 that is greater than the length L2 of the panels into which the laminate substrate 20 is to be divided. Therefore, the length E of the embossed structure measured along the length of the laminate substrate 20 is greater than the length L2 of the panels. Figure 6 Indicated by a dashed line.

[0255] The length L2 of the panel (shown in dotted lines) does not coincide with the length E of the embossed structure (shown in dashed lines), as shown in FIG. Figure 8 shown.

[0256] from Figure 8 As can be seen in , the perimeter C2 of the embossing device divided by the length L2 of the panel is a non-integer n. The non-integer n may be greater than 1, such as 1.1-1.9. In other examples, the non-integer may be in the range of 2.1-2.9. More generally, the non-integer may be in the range of integer n+0.1 to integer n+0.9, such as in the range of 1.1-1.9 or 2.1-2.9 or 3.1-3.9. The integer may be selected to avoid unnecessary repetition, such as avoiding the integer being equal to n+0.5, such as 1.5, 2.5, etc. Therefore, the non-integer may be in the range of integers n+0.1 to n+0.4 and n+0.6 to n+0.9; for example, 1.1-1.4, 1.6-1.9, 2.1-2.4, 2.6-2.9, 3.1-3.4, 3.6-3.9, etc.

[0257] The circumference C2 of the embossing device may be at least 110% of the panel length L2. The circumference C2 of the embossing device may be 110 - 190% of the panel length L2.

[0258] Thus, the number of different panels obtained from each laminate substrate 20 can be increased. Since the embossed structure is displaced between the panels, the panels will look different. The embossed structure is displaced from one panel to another, seen in the length direction of the panels. The embossed structure of each panel obtained from each laminate substrate can be varied, thereby increasing the number of different panels obtained.

[0259] exist Figure 8 In the example shown, 10 panels with different embossed structures are obtained. In the known solution, only 2 panels with different embossed structures can be obtained.

[0260] In addition, in terms of the panel pattern, the number of different panels obtained from each laminate substrate 20 can also be increased. The length L2 of the panel (shown in dotted lines) can be inconsistent with the length of the pattern. The length of the pattern can be consistent with the length E of the embossed structure. Since the pattern is shifted between the panels, the panels look different. The pattern can be shifted from one panel to another panel in the length direction of the panel.

[0261] The embossed structure may be aligned or at least partially aligned with the print. If the printed polymer base film 1 is printed by rotogravure, the circumference C1 of the gravure cylinder 2 may substantially correspond to the circumference C2 of the embossing device 30. The circumference C2 of the embossing device 30 may correspond to the length E of the embossed structure of the panel. Thus, the embossed structure may be aligned or at least partially aligned with the print.

[0262] Regardless of the printing method, the pattern repeat length L may substantially correspond to the circumference C2 of the embossing device 30, so that the embossed structure may be aligned, or at least partially aligned, with the print.

[0263] In one example, the pattern repeat length does not correspond to the length E of the embossed structure. The polymer base film 1 may be printed with a pattern whose length substantially corresponds to the length of the polymer base film 1. The one or more patterns may include elements aligned with the embossed structure of the embossing device such that the embossed structure is partially aligned with the one or more patterns.

[0264] In the above disclosure the panels may be intended for use as building panels such as floor panels, furniture components, worktops, wall panels, ceiling panels.

[0265] List of entries:

[0266] Item 1. A method for producing a panel having an embossed structure, comprising:

[0267] A substrate (10; 10') is formed by a continuous process, wherein the substrate (10; 10') comprises a polymer-based material,

[0268] A polymer base film (1) printed with a print is provided, wherein the print comprises a pattern repeating portion, wherein the pattern repeating portion comprises one or more patterns (11, 12), wherein the pattern repeating portion has a pattern repeating length (R) measured along the length direction of the polymer base film (1),

[0269] The polymer base film (1) is applied on the substrate (10; 10'), the printed polymer base film (1) is continuously applied on the substrate (10; 10'),

[0270] pressing the polymer-based film (1) onto the substrate (10; 10') to form a laminated substrate (20), and

[0271] The laminated substrate (20) is embossed by an embossing device (31; 33) so that the laminated substrate (20) acquires an embossed structure,

[0272] dividing the laminate substrate (20) into a plurality of panels, each panel having a length (L2) and a width (W2), and

[0273] The pattern repeat length (R) divided by the length of the panel (L2) is a non-integer.

[0274] Item 2. A method according to Item 1, wherein the circumference (C2) of the embossing device (31; 33) corresponds to the pattern repeat length (R).

[0275] Item 3. The method according to item 1 or 2, wherein the pattern repeat length (R) is greater than the length (L2) of the panel.

[0276] Item 4. Method according to any of the preceding items, wherein the pattern repeat length (R) is at least 110%, such as in the range of 110-190%, of the length (L2) of the panel.

[0277] Item 5. The method according to any of the preceding items, wherein the embossed structure is at least partially aligned with the one or more patterns (11, 12).

[0278] Item 6. A method according to any one of the preceding items, wherein the polymer-based film (1) is printed by means of a rotary gravure cylinder (2), wherein the circumference (C1) of the rotary gravure cylinder (2) corresponds to the circumference (C2) of the embossing device (31; 33).

[0279] Item 7. The method according to any one of items 1 to 5, wherein the polymer-based film (1) is printed by digital printing such as inkjet printing.

[0280] Item 8. A method according to any of the preceding items, wherein the panels are planks or tiles.

[0281] Item 9. The method according to any one of the preceding items, wherein the substrate (10; 10') is formed by extrusion.

[0282] Item 10. The method according to any one of the preceding items, wherein the polymer-based film (1) is applied to the substrate (10; 10') before cooling the substrate (10; 10').

[0283] Item 11. The method according to any of the preceding items, further comprising applying a protective layer to the polymer base film prior to embossing.

[0284] Item 12. The method according to any one of the preceding items, wherein pressing comprises applying heat and pressure.

[0285] Item 13. The method according to any one of the preceding items, wherein the substrate (10; 10') further comprises a filler, the filler being one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, wood powder, crushed rice husk, cork, bamboo powder.

[0286] Item 14. The method according to any one of the preceding items, wherein the printed polymer-based film (1) is a PVC film.

Claims

1. A method for producing a panel having an embossed structure, the method comprising: The substrate (10; 10'), wherein the substrate (10; 10') comprises a polymer-based material, Providing a printed polymer base film (1), The printed polymer base film (1) is applied to the substrate (10; 10'), the printed polymer base film (1) is continuously applied to the substrate (10; 10') The printed polymer base film (1) is pressed onto the substrate (10; 10'), thereby forming a laminated substrate (20), and The laminated substrate (20) is embossed by an embossing device (31; 33) having a perimeter (C2), so that the laminated substrate (20) acquires an embossed structure, dividing the laminate substrate into a plurality of panels, each panel having a length (L2) and a width (W2), and The circumference (C2) of the embossing device (31; 33) divided by the length (L2) of the panel is a non-integer.

2. The method according to claim 1, wherein: The circumference (C2) of the embossing device (31; 33) is greater than the length (L2) of the panel.

3. The method according to claim 2, wherein: The circumference (C2) of the embossing device (31; 33) is at least 110% of the length (L2) of the panel.

4. The method according to any one of claims 1 to 3, wherein: The embossed structure is aligned with at least a portion of the pattern (11, 12) of the printed polymer-based film (1).

5. A method according to any one of the preceding claims, wherein: The pattern comprises a pattern repeat having a pattern repeat length (R), wherein the circumference (C2) of the embossing means (31; 33) substantially corresponds to the pattern repeat length (R).

6. A method according to any one of the preceding claims, wherein: The printed polymer-based film (1) is printed by a rotogravure cylinder (2), wherein the circumference (C1) of the rotogravure cylinder (2) substantially corresponds to the circumference (C2) of the embossing device (31; 33).

7. The method according to any one of claims 1 to 5, wherein: The polymer base film (1) is printed by digital printing.

8. A method according to any one of the preceding claims, wherein: The panels are either planks or tiles.

9. A method according to any one of the preceding claims, wherein: The substrate (10; 10') is formed by extrusion.

10. A method according to any one of the preceding claims, wherein: The printed polymer-based film (1) is applied to the substrate (10; 10') before cooling the substrate (10, 10').

11. The method according to any one of the preceding claims, further comprising applying a protective layer (18) on the printed polymer base film (1) prior to embossing.

12. A method according to any one of the preceding claims, wherein: Pressing involves the application of heat and pressure.

13. A method according to any one of the preceding claims, wherein: The substrate (10; 10') further comprises a filler, which is one or more of the following: calcium carbonate, chalk, limestone, talc, stone powder, fly ash, wood powder, crushed rice husk, cork, bamboo powder.

14. A method according to any one of the preceding claims, wherein: The printed polymer base film (1) is a PVC film.

15. A method according to any one of the preceding claims, wherein: The method includes producing a plurality of panels.

16. The method according to claim 15, wherein: The method comprises producing at least 10 panels, wherein on half of the panels the pattern is repeated and the panels where the pattern is repeated have a different embossing pattern so that the panels are all different.

Images