Method for producing building panel having bevel

Abstract

A building panel (1) and a method for manufacturing such a building panel (1), wherein the building panel (1) may be, for example, a floor panel or a wall panel. The method comprises bonding the substrate material and the sub-layer material to form a substrate (3) and a sub-layer (5) of the building panel (1). The method further comprises applying a surface layer (7) on the sub-layer (5), applying pressure to form the building panel (1), and forming a slope along at least one edge (15, 16, 17, 18) of the building panel (1) by means of a pressing device. The sub-layer (5) is configured to be at least partially plastically deformed when a pressure is applied so as to form at least a slope of the building panel (1).

Description

Technical Field

[0001] The inventive concept relates to a building panel, such as a floor panel or a wall panel, to a panel blank from which the building panel can be manufactured, and to a method for manufacturing such a building panel. In particular, the inventive concept relates to a building panel having a bevel and to a method for manufacturing such a bevel. Background Art

[0002] Architectural panels such as luxury vinyl tiles (LVT) or stone plastic composite panels (SPC panels) are very popular examples of architectural panels, especially floor panels, which have the advantages of being durable and easy to maintain.

[0003] SPC panels are stiffer panels than LVT panels, with an elastic modulus of 2000-12000 MPa, and typically contain 50-90 wt% of inorganic fillers, such as chalk. LVT panels typically have an elastic modulus of less than 2000 MPa.

[0004] However, such panels usually have limitations and disadvantages in their manufacturing process, because the cores of these panels are usually made of highly filled thermoplastic materials, thermosetting materials, hardwood substrates or inorganic materials such as mineral-based materials. These types of cores are usually very hard, so it is difficult to form desired embossing and / or bevels thereon. For example, if SPC panels or another thermoplastic board are laminated, embossed and / or provided with bevels, it is necessary to use a large amount of surface materials to achieve the appropriate and desired shape of the embossing and / or bevels. In addition, if highly filled thermoplastic boards or mineral substrates such as MgO boards are laminated with thin thermoplastic decorative layers, it is also difficult to obtain suitable embossing and / or bevels.

[0005] In the manufacturing processes used today, this disadvantage is overcome by using high temperatures, high pressures, long pressing times and / or thick material layers such as powders or surface layers. This results in an inefficient manufacturing process or a manufacturing process that is expensive and consumes material. Summary of the invention

[0006] It is an object of at least one embodiment of the present invention to provide an improvement over the known technology. This object can be achieved by the technology defined herein.

[0007] In a first aspect of the present disclosure, there is provided a method for manufacturing a building panel, such as a floor panel or a wall panel, the method comprising:

[0008] combining a substrate material and a sublayer material to form a substrate and a sublayer of a building panel, wherein the sublayer material comprises a polymer-based material;

[0009] applying a surface layer over the sublayer;

[0010] applying pressure to form the building panel; and

[0011] forming a bevel along at least one edge of the building panel by applying pressure by means of a pressing device,

[0012] Wherein the sub-layer is configured to at least partially plastically deform when pressure is applied so as to form at least a sloped surface of the building panel.

[0013] In one embodiment, the step of applying pressure by a pressing device to form the bevel may be performed after applying pressure to form the building panel.Applying pressure to form the building panel may be performed separately from applying pressure to form the bevel.

[0014] In one embodiment, applying pressure to form the building panel may occur substantially simultaneously with forming the bevel by applying pressure.Applying pressure to form the bevel and applying pressure to form the building panel may be performed in one pressing operation.

[0015] The pressure applied when forming the building panels may be 5-20 bar.

[0016] The substrate material and the sub-layer material may be combined when pressure is applied to form the building panel.

[0017] When pressure is applied to form the building panel, the surface layer may be attached to the sub-layer.

[0018] By forming the bevel surface by plastic deformation in the sub-layer, a bevel surface can be formed in a highly filled substrate. In addition, the plastic deformation in the sub-layer at least partially reduces the amount of surface material required to form the bevel surface.

[0019] In one embodiment the step of applying pressure to form the building panels further comprises applying heat.

[0020] The temperatures applied when forming building panels may be 120-160°C.

[0021] In another embodiment the step of forming a bevel along at least one edge portion of the building panels by means of a pressing device further comprises applying heat.

[0022] In one embodiment, the temperature in the material when the bevel is formed is 40-220°C, or 75-180°C, and this may depend on various characteristics, such as the thickness of the material, the type of material.

[0023] In one embodiment, the pressure used to form the bevel is 1-50 bar or 1-30 bar, or 1-20 bar. The pressure applied may depend on the temperature of the material when the bevel is formed.

[0024] In one embodiment, the bonding of the substrate material and the sub-layer material is performed by an extrusion process. The bonding of the substrate material and the sub-layer material may also include a calendaring process.

[0025] In another embodiment, the bonding of the substrate material and the sub-layer material is performed by a calendaring process.

[0026] In yet another embodiment, the bonding of the substrate material and the sub-layer material is performed by a pressing process, preferably a continuous pressing process.

[0027] In one embodiment the step of applying pressure to form the building panels is performed by a continuous press, wherein the building panels are continuously transportable in a direction passing through the continuous press.

[0028] In an alternative embodiment the step of applying pressure to form the building panels is performed by a static pressing device, wherein the building panels can be placed under and / or on the static pressing device, remain there during the pressing time and be removed after the pressing process.

[0029] Furthermore, the pressing device for forming the inclined surface may be a single pressing device or a plurality of pressing devices, a static pressing device or a continuous pressing device.

[0030] The pressing device for forming the inclined surface may be provided with a protruding portion configured to form the inclined surface during pressing.

[0031] The bevel may have any shape, such as a V-shape, a U-shape or an arc.The bevel may be formed in the surface layer, and preferably also in the sub-layers, in a direction substantially perpendicular to a plane defined by the front surface of the building panels.

[0032] The shape and size of the bevel may depend on the thickness of the building panels and / or the total thickness of the surface layer and sub-layers. In one embodiment, the shape and size of the bevel may depend on the size and position of the mechanical locking means, as described in more detail below.

[0033] The bevel may extend 0.2 to 1 mm in a direction perpendicular to the plane defined by the front surface of the building panels. In an embodiment in which the building panels have a thinner thickness, for example in the range of 2 to 5 mm, the bevel may preferably extend 0.2 to 0.5 mm in a direction perpendicular to the front surface of the building panels. In another embodiment in which the building panels have a thicker thickness, for example in the range of 5 to 10 mm, the bevel may preferably extend 0.5 to 1 mm in a direction perpendicular to the front surface of the building panels.

[0034] The bevel may further be curved with a radius of 1 mm to 10 mm.

[0035] As mentioned above, the bevel may even further rely on a mechanical locking device. In one embodiment, the mechanical locking device extends in a direction parallel to the plane defined by the front surface of the building panel and extends further into the building panel than the bevel extends. In one embodiment, the tongue and groove of the mechanical locking device extends in a direction parallel to the plane defined by the front surface of the building panel and extends further into the building panel than the bevel extends. In another embodiment, the locking groove of the mechanical locking device extends in a direction parallel to the plane defined by the front surface of the building panel and extends further into the building panel than the bevel extends.

[0036] In one embodiment, the pressing device for forming the bevel can be configured to press a pattern or structure into the bevel during the formation of the bevel. For example, it may be desirable to have an embossing in the bevel that follows a specific pattern in the decorative layer of the surface layer, for example, to enhance the decorativeness of the decorative layer in the bevel. Such embossing can be formed into depressions and / or protrusions, for example, by pressing at a temperature range of 10-300° C., such as 50-220° C., such as 75° C. to 180° C. and at a pressure range of 1-100 bar, such as 1-50 bar, such as 1-30 bar for a time of 0.1-500 seconds, such as 0.5-300 seconds, such as 1-60 seconds.

[0037] The method may then further comprise a cooling process after forming the bevel and / or building panel. By adding a cooling step, it is easier to control the elasticity and / or recovery effect of the material in the bevel and / or building panel and thereby control the final appearance of the bevel of the building panel. Another advantage of having a cooling step is that it may provide a wider range of materials that can be used for the building panels, as different materials may tend to elastically return and / or recover at different temperatures, and by adding cooling, the elasticity and / or recovery process may be stopped.

[0038] The cooling process is preferably an active process in order to reduce the time compared to lowering the material temperature by the surrounding environment. The cooling process can be achieved by a cooling device using air, liquid, gas, solid material and / or other suitable means. The cooling device can cool by, for example, blowing, spraying, evaporation and / or contact.

[0039] The cooling process can be configured to reduce the temperature of the area of ​​the material forming the bevel by 15% to 40%. Depending on the type of cooling used by the cooling device and the temperature of such cooling, the time taken for the cooling process can vary. For example, if cold water is used, the cooling process may take 2 seconds to 20 seconds, while if cold air is used, the cooling process may take 30 seconds to 2 minutes, all depending on the type and temperature of cooling.

[0040] In one embodiment, the polymer-based material of the sub-layer forming the sub-layer is a thermoplastic material.

[0041] The thermoplastic material of the sublayer material can be selected from the group including the following materials: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0042] The sub-layer material may comprise a polymer-based material, such as a thermoplastic material, in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0043] The sub-layer material may comprise a polymer-based material such as a thermoplastic material in an amount of 10-95 wt%, 15-85 wt%, or 20-70 wt%.

[0044] In one embodiment, the sub-layer material may include at least one filler.

[0045] The filler of the sub-layer material may include at least one or more of an organic filler, an inorganic filler, and a combination thereof. The filler has advantages such as improving layer characteristics and being cost effective.

[0046] Examples of organic fillers are coconut or bamboo fibres, wood flour and rice husks. These types of organic fillers are generally low cost and readily available. The sub-layer may contain an amount of 1-70 wt % organic filler, or an amount of 30-70 wt % organic filler.

[0047] Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or combinations thereof. These types of fillers are particularly cost-effective and readily available.

[0048] In one embodiment, the sub-layer material comprises a mineral-based filler.

[0049] The sub-layer material may contain mineral-based fillers in an amount of 1-80 wt%.

[0050] The sub-layer material may comprise the mineral-based filler in an amount of at least 20 wt % or at least 30 wt %.

[0051] The mineral-based filler of the sub-layer material may be calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

[0052] In addition, the sublayer material may contain a plastisol. A plastisol is a composition of PVC particles suspended in a plasticizer. A plastisol may also contain usually small amounts of extenders, stabilizers, pigments and / or fillers. The weight ratio between PVC particles and plasticizer is preferably 50 / 50.

[0053] In one embodiment, the sublayer material consists of plastisol.

[0054] The plastisol imparts soft and durable properties to the sublayer.The sublayer may be formed from the plastisol.

[0055] The sub-layer material is configured to at least partially plastically deform when pressure is applied so as to form at least the inclined surface of the building panel.In order to make the sub-layer material plastically deformable, the material may comprise a plasticizer or comprise at least two different types of polymers, as described below.

[0056] Thus, the sublayer material may contain a plasticizer selected from any one of the group consisting of ortho-phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The sub-layer material forming the sub-layer may contain a plasticizer in an amount of 1-30 wt% or 2-15 wt%. The plasticizer provides the sub-layer with desirable formable properties.

[0057] Another method of producing the desired formable properties of the sub-layer material is that the sub-layer material comprises at least two different types of polymers. For example, the sub-layer may comprise a material blend comprising a PVC / PVAc copolymer, wherein the PVAc content in the material blend of the sub-layer may be 1-20 wt%, and the PVC content in the material blend may be 80-99 wt%.

[0058] In yet another embodiment, the sub-layer material comprises less than 10 wt% wood-based material, or less than 5 wt% wood-based material, such as 0.5-10 wt% wood-based material.

[0059] The sublayer may have a thickness of 0.1-2 mm, a thickness of 0.2-1 mm, or a thickness of 0.3-1 mm.

[0060] The density of the sublayer can be 1.0g / cm 3 Up to 2.5g / cm 3 For example, if the sublayer comprises a plastisol, the density of the sublayer may be as low as 1.0-1.4 g / cm 3 .

[0061] In one embodiment, the sublayer is foamed / foamed. The sublayer may be foamed and have a density reduction of at least 10%, at least 20%, or at least 30% compared to a non-foamed sublayer of the same sublayer material. One advantage of a foamed sublayer is that it can reduce the weight of the layer. In addition, the foamed sublayer material may not rebound to the same extent as a non-foamed sublayer material after forming, for example, a ramp.

[0062] In one embodiment, the substrate may be a single layer substrate, and in another embodiment, may be a multi-layer substrate.

[0063] In one embodiment, the substrate material forming the substrate may include a polymer-based material and a filler.

[0064] The polymer-based material of the substrate material can be a thermoplastic material, wherein the thermoplastic material can be selected from the group consisting of polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0065] The substrate material may comprise a polymer-based material, such as a thermoplastic material, in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0066] The substrate material may comprise a polymer-based material, such as a thermoplastic material, in an amount of 10-60 wt%, 15-50 wt% or 20-30 wt%.

[0067] The substrate material may also include a thermoset material, such as epoxy, polyurethane, cross-linked polyethylene (PEX), aminoplast, phenolic plastic, acrylate, and / or combinations thereof.

[0068] Thermoset based substrate materials may contain 10-70 wt%, 20-60 wt% or 25-50 wt% of a thermosetting resin such as an aminoplast, polyurethane, phenolic plastic, epoxy resin or acrylic resin.

[0069] Such substrate materials may also contain 0-70 wt%, 10-70 wt% or 20-70 wt% of a filler, such as an inorganic filler.

[0070] The substrate material may also include mineral-based materials such as magnesium oxide (MgO), magnesium chloride (MgCl2), magnesium sulfate (MgSO4) or sand / sand. The substrate material based on these types of mineral materials may also include 1-20wt% or 5-15wt% fillers, such as organic fillers, such as fibers from rice husks or coconut or bamboo.

[0071] Another suitable mineral based material is for example Portland cement. A substrate material based on this type of mineral material may be referred to as a fiber cement board and may further comprise sand and / or 1-20 wt% or 5-15 wt% of a filler, such as an organic filler.

[0072] The mineral-based substrate material may include at least 50 wt%, at least 60 wt%, at least 70 wt% or at least 80 wt% of the mineral-based material. The filler of the substrate material may include at least one or more of an organic filler, an inorganic filler and a combination thereof.

[0073] Examples of organic fillers are rice husks and fibres of coconut or bamboo. These types of organic fillers are generally low cost and readily available. The substrate may comprise 1-70 wt % of the organic filler, for example 30-70 wt % of the organic filler.

[0074] Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or combinations thereof. These types of fillers are particularly cost-effective and readily available.

[0075] In one embodiment, the substrate material comprises a mineral based filler.

[0076] The substrate material may contain the mineral-based filler in an amount of 30-90 wt%.

[0077] The mineral-based filler of the substrate material may be calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

[0078] The substrate may further comprise a plasticizer selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The substrate material forming the substrate may include the plasticizer in an amount of 1-30 wt % or 2-15 wt %.

[0079] Typical SPC substrates that can be preferably used for such applications may contain 10-40wt%, 15-35wt%, or 20-30wt% of thermoplastic materials, such as PVC. The SPC core may also contain 50-90wt%, 60-80wt%, or 65-75wt% of inorganic fillers, such as chalk. The SPC core may also contain 0-20wt%, 1-15wt%, or 2-10wt% of additives, such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0080] Typical LVT substrates that may also be preferred for this type of application will have a material content similar to that of the SPC substrates described above, i.e., 10-40 wt%, 15-35 wt%, or 20-30 wt% of thermoplastic material such as PVC. The SPC core may also contain 50-90 wt%, 60-80 wt%, or 65-75 wt% of an inorganic filler such as chalk. The SPC core may also contain 0-20 wt%, 1-15 wt%, or 2-10 wt% of additives such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0081] In one embodiment, the substrate material comprises less than 10 wt% wood-based material, or less than 5 wt%, such as 0.5-10 wt% wood-based material.

[0082] In one embodiment, the surface layer may include a decorative layer. The decorative layer may be a colored powder layer, paper, a polymer-based board, a wood-based board, a wood veneer layer, a cork-based board, or a fabric (woven or non-woven).

[0083] In one embodiment, the surface layer comprises a decorative layer comprising a printed polymer-based sheet.

[0084] Furthermore, the surface layer may comprise a wear-resistant layer, such as a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a paint layer and / or a coating.

[0085] The method may further include:

[0086] Before beveling along at least one edge of the building panels by means of a pressing device, a notch is produced in an edge portion of at least one edge of the building panels.

[0087] The step of creating the notch in the edge portion may be performed by a milling process or any other process suitable for removing material.

[0088] In one embodiment the notch may be located in a rear part of the building panel.The notch may be located in a rear surface of the building panel opposite to the surface layer.

[0089] In an alternative embodiment, the indentations may be located at a distance from the surface of the building panels in a direction perpendicular to said surface. If the surface is the front surface of the building panels, the distance from the surface of the building panels may preferably correspond at least to the thickness of the wear layer, if any wear layer is present, or at least to the thickness of the surface layer of the building panels. In an embodiment, the indentations are arranged in a substrate of the building panels. In an alternative embodiment, the indentations are arranged partly in the substrate and partly in the surface layer.

[0090] Furthermore, the notch may extend in a direction parallel to the front and / or back surface of the building panel and parallel to the extension length of the edge in which the notch is created. In one embodiment the notch extends along the entire length of the edge of the building panel in which the notch is created.

[0091] The characteristics and dimensions of the notches may vary depending on, for example, the material of the layer in which the notches are created, the intended dimensions of the bevel, or the intended finishing / finishing / calibrating process, for example in case the building panels shall comprise mechanical locking means.

[0092] The notch may preferably extend into the building panels in a direction parallel to a plane defining the front surface of the building panels over a length that is equal to or greater than the extension length of the intended chamfer to be formed.

[0093] In embodiments in which the mechanical locking means are to be formed in the building panels, the notch may preferably extend into the building panels in a direction parallel to a plane defining the front surface of the building panels, not extending beyond the mechanical locking means, or even more preferably extending shorter than the mechanical locking means.

[0094] In another embodiment, the tongue and groove of the mechanical locking means to be formed, after forming, extends into the building panel further than the notch in a direction parallel to the plane defined by the front surface of the building panel. In yet another embodiment, the locking groove of the mechanical locking means to be formed, after forming, extends into the building panel further than the notch in a direction parallel to the plane defined by the front surface of the building panel. This is preferred, since the notch should not affect the process of forming the mechanical locking means or the dimensions of such a mechanical locking means. Therefore, after forming the chamfer, the remaining notch is preferably removed during the forming of the mechanical locking means.

[0095] In fact, whatever the final processing step along the edge of the building panel (e.g. finishing), after the beveling, the remaining notch is preferably removed in this final processing step. Thus, the notch may preferably be a temporary feature of the edge of the building panel, which no longer assumes its original shape during the final shaping process, i.e. the finishing process.

[0096] In one embodiment, the height of the opening of the notch before the bevel is formed is approximately equal to the height of the bevel.

[0097] In another embodiment, the height of the opening of the notch before the bevel is formed exceeds the height of the bevel.

[0098] In one embodiment the length of the notch into the building panel in a direction parallel to the front surface of the building panel is approximately equal to the radius of the bevel.

[0099] In one embodiment the length of the notch into the building panel in a direction parallel to the front surface of the building panel exceeds the radius of the bevel.

[0100] The method may further include:

[0101] Before forming the bevel along the at least one edge of the building panel, at least a region between the notch and the surface of the building panel is heated. The region may comprise a portion of the surface layer at the edge of the building panel where the notch is created. Alternatively, the region may comprise a portion of the surface layer and of the substrate at the edge of the building panel where the notch is created.

[0102] In one embodiment, the thickness of the area which is heated before the bevel is formed may correspond to the distance from where the notch is created to the surface of the building panel in a direction perpendicular to the surface of the building panel.

[0103] The method may further include:

[0104] After forming the bevel along at least one edge of the building panel, finishing the at least one edge of the building panel. Finishing the edge of the building panel may include performing a finishing step to produce the final shape and tolerance of the edge, bevel and building panel. Such a finishing step may be achieved, for example, by cutting, milling and / or grinding.

[0105] In one embodiment, the step of finishing the edge may comprise producing an edge surface substantially perpendicular to the front surface of the building panel.Such finishing may be achieved by cutting, milling and / or grinding, for example.

[0106] In an alternative embodiment, the step of finishing the edge may comprise creating an angled / inclined edge surface, wherein the edge of the front surface preferably protrudes from a plane arranged in the edge of the rear surface extending perpendicularly to the front surface. That is, the inclined surface preferably slopes towards the rest of the building panels from the front surface to the rear surface of the building panels.

[0107] In one embodiment, the edge surface resulting from the finishing step may be a continuous surface or a discontinuous surface comprising a plurality of segments.

[0108] The method may further include:

[0109] Along at least one edge of the building panels mechanical locking means are created, wherein the mechanical locking means are configured for locking similar or substantially identical building panels horizontally and / or vertically in an assembled position.

[0110] Producing mechanical locking devices can be seen as another example of finishing building panel edges.

[0111] The mechanical locking device may be arranged along the edges of the building panels. The mechanical locking device may comprise connecting means, so that similar or substantially identical building panels may be locked together. Furthermore, each edge may be provided with similar or different types of connecting means. Preferably, the connecting means arranged on opposite edges of the building panels are compatible with each other. The mechanical locking device may be provided with a first pair of connecting means and a second pair of connecting means. For example, the first pair of connecting means may be arranged along a first edge and an opposite second edge of the building panels, being compatible with each other. The second pair of connecting means may be arranged along a third edge and an opposite fourth edge of the building panels, being compatible with each other. In one embodiment, the first and second edges may be long sides of a building panel having a rectangular / cuboid shape and the third and fourth edges may be short sides of such a building panel.

[0112] The first pair of connection mechanisms and the second pair of connection mechanisms may be of the same type or two different types of mechanical locking devices.

[0113] In a second aspect of the inventive concept, there is provided a method of manufacturing a building panel, such as a floor panel or a wall panel, the method comprising:

[0114] combining a substrate material and a sublayer material to form a substrate and a sublayer of a panel stock, wherein the sublayer material comprises at least a polymer-based material;

[0115] applying a surface layer over the sublayer;

[0116] applying pressure to form the panel stock;

[0117] forming grooves in the panel stock by applying pressure by means of a pressing device and by plastic deformation of the sub-layers; and

[0118] Forming building panels from panel stock,

[0119] Wherein the groove is configured for forming a bevel along at least one edge of the building panel.

[0120] In one embodiment, applying pressure to form the panel blank may occur substantially simultaneously with forming the bevel by applying pressure. Applying pressure to form the bevel and applying pressure to form the panel blank may be performed in one pressing operation.

[0121] The pressure applied when forming the panel blank may be 5-20 bar.

[0122] The substrate material and sub-layer material may bond when pressure is applied to form the panel blank.

[0123] When pressure is applied to form the panel stock, the surface layer may be attached to the sub-layer.

[0124] The method defined above is advantageous for at least the following reasons: By forming the grooves by plastic deformation in the sublayer, grooves can be formed in a highly filled substrate. Furthermore, the plastic deformation in the sublayer at least partially reduces the amount of surface material required to form the grooves.

[0125] In one embodiment, the sub-layer material may further comprise at least one filler.

[0126] In one embodiment, the step of applying pressure to at least form a panel blank further comprises applying heat.

[0127] The temperature applied when forming the panel stock may be 120-160°C.

[0128] In another embodiment, the step of applying pressure to form at least the grooves in the panel stock further comprises applying heat.

[0129] In one embodiment, the bonding of the substrate material and the sub-layer material is performed by an extrusion process. The bonding of the substrate material and the sub-layer material may also include a calendaring process.

[0130] In another embodiment, the bonding of the substrate material and the sub-layer material is performed by a pressing process.

[0131] In one embodiment, the grooves are formed in the panel stock while forming the panel stock.

[0132] In another embodiment, the step of forming the grooves in the panel stock further comprises applying heat.

[0133] In one embodiment, the temperature in the material when the bevel is formed is 40-220°C, or 75-180°C, and this may depend on various characteristics, such as the thickness of the material, the type of material.

[0134] In one embodiment, the pressure used to form the grooves is 1-50 bar or 5-30 bar.

[0135] In an alternative embodiment, the forming of the grooves in the panel blank and the forming of the panel blank are done in separate pressing processes, wherein preferably the forming of the grooves is effected after the forming of the panel blank.

[0136] In one embodiment, the step of applying pressure to form the panel blank may be performed by a continuous press, wherein the building panel may be continuously conveyed at a speed in a direction passing through the continuous press.

[0137] In an alternative embodiment, the step of applying pressure to form the panel blank is performed by a static pressing device, wherein the panel blank can be placed in the static pressing device, kept there during the pressing time, and removed after the pressing process.

[0138] In addition, no matter whether it is a continuous pressing device or a static pressing device, the pressing device can include at least one protrusion, and the at least one protrusion is configured to form a groove in the panel original plate. In one embodiment, the pressing device can include a plurality of protrusions, so that a plurality of grooves are pressed out simultaneously in the panel original plate.

[0139] The groove may have any shape, such as V-shaped, U-shaped or circular.The groove may extend into the surface layer, and preferably into the sub-layer, in a direction substantially perpendicular to the plane formed by the front surface of the panel stock.

[0140] In one embodiment, the pressing device for forming the groove may be configured to press a pattern or structure into the groove during the formation of the groove. For example, it may be desirable to have an embossing in the groove, and thus in the bevel of the finished building panel, to follow a specific pattern in the decorative layer of the surface layer, for example to enhance the decorative properties of the decorative layer in the bevel.

[0141] Such embossing can be carried out, for example, at a temperature range of 10-300°C, such as 50-220°C, such as 75°C to 180°C, and a pressure range of 1-100 bar, such as 1-50 bar, such as 1-30 bar, for 0.1-500 seconds, such as 0.5-300 seconds, such as 1-60 seconds to form depressions and / or protrusions.

[0142] The method may further comprise cooling after forming the grooves and / or after forming the panel blank. By adding a cooling step, the elasticity and / or recovery effect of the material in the grooves and / or panel blank may be more easily controlled, which in turn may control the final appearance of the bevel of the building panel. Another advantage of having a cooling step is that it may provide a wider range of materials that may be used for the building panels, as different materials may tend to elastically return and / or recover at different temperatures, and by adding cooling, the elasticity and / or recovery process may be stopped.

[0143] The cooling process is preferably an active process in order to reduce the time compared to lowering the material temperature by the surrounding environment. The cooling process can be achieved by a cooling device using air, liquid, gas, solid material and / or other suitable means. The cooling device can cool by, for example, blowing, spraying, evaporation and / or contact.

[0144] The cooling process may be configured to reduce the temperature of the area where the slope of the material is formed by 15% to 40%. Depending on the type of cooling used by the cooling device and the temperature of such cooling, the time taken for the cooling process may vary. For example, if cold water is used, the cooling process may take 2 seconds to 20 seconds, and if cold air is used, the cooling process may take 30 seconds to 2 minutes, all depending on the type and temperature of cooling.

[0145] In one embodiment the step of forming the building panels from the panel stock comprises dividing the panel stock into building panels at the grooves.Thereby, the grooves will form the bevel of the building panel along the edges.

[0146] In one embodiment, the polymer-based material of the sub-layer forming the sub-layer is a thermoplastic material.

[0147] The thermoplastic material of the sublayer material can be selected from the group including the following materials: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0148] The sub-layer material may comprise a polymer-based material such as a thermoplastic material in an amount of at least 10 wt%, at least 15 wt%, or at least 20 wt%.

[0149] The sub-layer material may comprise a polymer-based material such as a thermoplastic material in an amount of 10-95 wt%, 15-85 wt%, or 20-70 wt%.

[0150] The filler of the sub-layer material may include at least one or more of an organic filler, an inorganic filler, and a combination thereof. The filler has advantages such as improving layer characteristics and being cost effective.

[0151] Examples of organic fillers are coconut or bamboo fibres, wood flour and rice husks. These types of organic fillers are generally low cost and readily available. The sub-layer may comprise 1-70 wt % of the organic filler, or 30-70 wt % of the organic filler.

[0152] Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or combinations thereof. These types of fillers are particularly cost-effective and readily available.

[0153] In one embodiment, the sub-layer material comprises a mineral-based filler.

[0154] The sub-layer material may contain mineral-based fillers in an amount of 1-80 wt%.

[0155] The sub-layer material may comprise the mineral-based filler in an amount of at least 20 wt % or at least 30 wt %.

[0156] The mineral-based filler of the sub-layer material may be calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

[0157] In addition, the sublayer material may contain a plastisol. A plastisol is a composition of PVC particles suspended in a plasticizer. A plastisol may also contain usually small amounts of extenders, stabilizers, pigments and / or fillers. The weight ratio between PVC particles and plasticizer is preferably 50 / 50.

[0158] In one embodiment, the sublayer material consists of plastisol.

[0159] The plastisol imparts soft and durable properties to the sublayer.The sublayer may be formed from the plastisol.

[0160] The sublayer material is configured to at least partially plastically deform when pressure is applied so as to form at least the grooves of the panel stock. In order to make the sublayer material plastically deformable, the material may contain a plasticizer or contain at least two different types of polymers, as described below.

[0161] Thus, the sub-layer material may contain a plasticizer selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The sub-layer material forming the sub-layer may contain a plasticizer in an amount of 1-30 wt% or 2-15 wt%.The plasticizer provides the sub-layer with desirable formable properties.

[0162] In another embodiment, the sublayer material comprises at least two different types of polymers. For example, the sublayer may include a material blend containing a PVC / PVAc copolymer, wherein the PVAc content in the material blend of the sublayer may be 1-20 wt%, and the PVC content in the material blend may be 80-99 wt%.

[0163] In yet another embodiment, the sub-layer material comprises less than 10 wt % wood-based material, or less than 5 wt % wood-based material.

[0164] The sublayer may have a thickness of 0.1-2 mm, a thickness of 0.2-1 mm, or a thickness of 0.3-1 mm.

[0165] The density of the sublayer can be 1.0g / cm 3 Up to 2.5g / cm 3 For example, if the sublayer comprises plastisol, the density of the sublayer can be as low as 1.0-1.4 g / cm 3 .

[0166] In one embodiment, the sublayer is foamed. The sublayer may be foamed and have a density reduction of at least 10%, at least 20%, or at least 30% compared to a non-foamed sublayer of the same sublayer material. One advantage of a foamed sublayer is that it reduces the weight of the layer. In addition, the foamed sublayer material may not rebound to the same extent as a non-foamed sublayer material after forming, for example, a ramp.

[0167] In one embodiment, the substrate may be a single layer substrate, and in another embodiment, may be a multi-layer substrate.

[0168] In one embodiment, the substrate material forming the substrate comprises a polymer-based material and a filler.

[0169] The polymer-based material of the substrate material can be a thermoplastic material, wherein the thermoplastic material can be selected from the group consisting of polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0170] The substrate material may comprise a polymer-based material such as a thermoplastic material in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0171] The substrate material may comprise a polymer-based material such as a thermoplastic material in an amount of 10-60 wt%, 15-50 wt% or 20-30 wt%.

[0172] The substrate material may also include a thermoset material, such as epoxy, polyurethane, cross-linked polyethylene (PEX), aminoplast, phenolic plastic, acrylate, and / or combinations thereof.

[0173] The substrate material based on thermosetting material can contain 10-70wt%, 20-60wt% or 25-50wt% of thermosetting resin, such as amino plastic, polyurethane, phenolic plastic, epoxy resin or acrylic resin. Such substrate material can also contain 0-70wt%, 10-70wt% or 20-70wt% of filler, such as inorganic filler.

[0174] The substrate material may also include mineral-based materials such as magnesium oxide (MgO), magnesium chloride (MgCl2), magnesium sulfate (MgSO4) or sand / sand. The substrate material based on these types of mineral materials may also include 1-20wt% or 5-15wt% fillers such as organic fillers, such as wood fibers.

[0175] Another suitable mineral based material is for example Portland cement. A substrate material based on this type of mineral material may be referred to as a fiber cement board and may further comprise sand and / or 1-20 wt% or 5-15 wt% of a filler, such as an organic filler.

[0176] The substrate material based on a mineral-based material may comprise at least 50 wt%, at least 60 wt%, at least 70 wt% or at least 80 wt% of the mineral-based material.

[0177] The filler of the substrate material may include at least one or more of an organic filler, an inorganic filler, and a combination thereof.

[0178] Examples of organic fillers are coconut or bamboo fibres and rice husks. These types of organic fillers are generally low cost and readily available. The substrate may comprise 1-70 wt % of the organic filler, or 30-70 wt % of the organic filler.

[0179] Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or combinations thereof. These types of fillers are particularly cost-effective and readily available.

[0180] In one embodiment, the substrate material comprises a mineral based filler.

[0181] The substrate material may contain 30-90 wt% of a mineral based filler.

[0182] The mineral based filler of the substrate material may be calcium carbonate (CaCO3).

[0183] The substrate may further comprise a plasticizer selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The substrate material forming the substrate may contain 1-30 wt % or 2-15 wt % of a plasticizer.

[0184] Typical SPC substrates that can be preferably used for such applications may contain 10-40wt%, 15-35wt%, or 20-30wt% of thermoplastic materials, such as PVC. The SPC core may also contain 50-90wt%, 60-80wt%, or 65-75wt% of inorganic fillers, such as chalk. The SPC core may also contain 0-20wt%, 1-15wt%, or 2-10wt% of additives, such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0185] A typical LVT substrate that may also be preferably used for this type of application will have a material content similar to that of the SPC substrate described above, i.e., 10-40wt%, 15-35wt% or 20-30wt% of thermoplastic material, 50-90wt%, 60-80wt% or 65-75wt% of inorganic filler and 0-20wt%, 1-15wt% or 2-10wt% of additives, but with 1-20wt%, 2-15wt% or 3-10wt% of plasticizer added.

[0186] In one embodiment, the substrate material comprises less than 10 wt % wood-based material, or less than 5 wt % wood-based material.

[0187] In one embodiment, the surface layer may include a decorative layer. The decorative layer may be a colored powder layer, paper, a polymer-based board, a wood-based board, a wood veneer layer, a cork-based board, or a fabric (woven or non-woven).

[0188] In one embodiment, the surface layer comprises a decorative layer comprising a printed polymer-based sheet.

[0189] Furthermore, the surface layer may comprise a wear-resistant layer, such as a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a paint layer and / or a coating.

[0190] In one embodiment, the method further comprises:

[0191] After forming the building panel from the panel stock, at least one edge of the building panel is finished. Finishing the edge of the building panel may include performing a finishing step to produce the final shape and tolerance of the edge and the building panel. Such a finishing step may be achieved by cutting, milling and / or grinding, for example.

[0192] In one embodiment, the step of finishing the edge may comprise producing an edge surface substantially perpendicular to the front surface of the building panel.Such finishing may be achieved by cutting, milling and / or grinding, for example.

[0193] In an alternative embodiment, the step of finishing the edge may comprise creating an angled / inclined edge surface, wherein the edge of the front surface preferably protrudes from a plane arranged in the edge of the rear surface extending perpendicularly to the front surface. That is, the inclined surface preferably slopes towards the rest of the building panels from the front surface to the rear surface of the building panels.

[0194] In one embodiment, the edge surface resulting from the finishing step may be a continuous surface or a discontinuous surface comprising a plurality of segments.

[0195] The method may further include:

[0196] After forming the building panels from the panel stock, mechanical locking means are produced along at least one edge of the building panels, wherein the mechanical locking means are configured for locking similar or substantially identical building panels horizontally and / or vertically in an assembled position.

[0197] Producing mechanical locking devices can be seen as another example of finishing building panel edges.

[0198] The mechanical locking means may be arranged along the edges of the building panels. The mechanical locking means may comprise connecting means, so that similar or substantially identical building panels may be locked together. Furthermore, each edge may be provided with similar or different types of connecting means. Preferably, the connecting means arranged on opposite edges of the building panels are compatible with each other. The mechanical locking means may be provided with a first pair of connecting means and a second pair of connecting means. For example, the first pair of connecting means may be arranged along a first edge and an opposite second edge of the building panel 1, being compatible with each other. The second pair of connecting means may be arranged along a third edge and an opposite fourth edge of the building panel, being compatible with each other. In one embodiment, the first and second edges may be the long sides of a building panel having a rectangular / cuboid shape and the third and fourth edges may be the short sides of such a building panel.

[0199] The first pair of connection mechanisms and the second pair of connection mechanisms may be of the same type or two different types of mechanical locking devices.

[0200] In a third aspect of the inventive concept there is provided a building panel manufactured by any one of the methods described above.

[0201] In a fourth aspect of the inventive concept, there is provided a method for forming a bevel along at least one edge of a building panel, the method comprising:

[0202] forming a building panel comprising a substrate, a sublayer and a surface layer, wherein the sublayer is arranged between the substrate and the surface layer, and wherein the sublayer comprises a polymer-based material; and

[0203] A chamfer is formed along at least one edge of the building panel by plastic deformation of the sub-layer.

[0204] In one embodiment forming the bevel along at least one edge of the building panel by plastic deformation of the sub-layer comprises applying pressure by a pressing device.

[0205] In another embodiment, forming the building panel comprises bonding the substrate, the sublayer and the surface layer by applying pressure to form the building panel.

[0206] Applying pressure by a pressing device to form the bevel may be performed after applying pressure to form the building panel (1).

[0207] In a fifth aspect of the inventive concept, there is provided a method for forming a bevel along at least one edge of a building panel, the method comprising:

[0208] forming a panel stock comprising a substrate, a sublayer and a surface layer, wherein the sublayer is disposed between the substrate and the surface layer, and wherein the sublayer comprises a polymer-based material; and

[0209] Forming grooves in the panel stock by plastic deformation of the sub-layers;

[0210] forming at least one building panel from the panel stock, and

[0211] Wherein the groove is configured for forming a bevel along at least one edge of the at least one building panel.

[0212] In one embodiment forming the groove along at least one edge of the building panel by plastic deformation of the sub-layer comprises applying pressure by a pressing device.

[0213] In another embodiment, forming the panel blank includes combining the substrate, the sublayer, and the surface by applying pressure to form the panel blank.

[0214] Applying pressure by a pressing device to form the grooves may be performed after applying pressure to form the building panel.

[0215] Furthermore, forming the building panels from the panel stock may comprise cutting the panel stock at the grooves. BRIEF DESCRIPTION OF THE DRAWINGS

[0216] Embodiments of the invention will now be described: Reference will be made to the accompanying drawings which illustrate non-limiting embodiments of how the concepts of the invention may be put into practice.

[0217] Figure 1A Schematically illustrates a building panel according to an embodiment of the inventive concept;

[0218] Figure 1B Schematically illustrates an alternative building panel according to an embodiment of the inventive concept;

[0219] Figure 2 Shows a building panel according to an embodiment of the inventive concept;

[0220] Figure 3A An assembly of a plurality of building panels is shown;

[0221] Figure 3B Shows Figure 3A Finished components;

[0222] Figure 4A schematically shows a cross section of two opposing edge portions of two adjacent building panels in an unassembled position, the two opposing edge portions comprising a mechanical locking device for locking two building panels together according to an embodiment of the inventive concept;

[0223] Figure 4B Schematically shows the assembled position Figure 4A A cross section of two opposite edge portions of;

[0224] Figure 4C Schematic diagram showing the assembly process Figure 4A A cross section of two opposite edge portions;

[0225] Figure 5A schematically shows a cross section of two opposing edge portions of two adjacent building panels in an unassembled position, the two opposing edge portions comprising a mechanical locking device for locking two building panels together according to another embodiment of the inventive concept;

[0226] Figure 5B Schematically shows the assembled position Figure 5A A cross section of two opposite edge portions of;

[0227] Figure 5C Schematic diagram showing the assembly process Figure 5A A cross section of two opposite edge portions;

[0228] Fig. 6A schematically shows a cross section of two opposing edge portions of two adjacent building panels in an unassembled position, the two opposing edge portions comprising a mechanical locking device for locking two building panels together according to a further embodiment of the inventive concept;

[0229] Figure 6B Schematically shows the assembled position Fig. 6A A cross section of two opposite edge portions of;

[0230] Figure 6C Schematic diagram showing the assembly process Fig. 6AA cross section of two opposite edge portions;

[0231] Fig. 7A and Figure 7B schematically illustrates the steps of a method for producing a building panel according to an embodiment of the inventive concept;

[0232] Fig. 8A and Figure 8B schematically illustrates the steps of a method for producing a building panel according to another embodiment of the inventive concept;

[0233] Fig. 9 Schematically illustrates a method for producing a building panel according to another embodiment of the inventive concept;

[0234] Fig. 10A Schematically illustrates a method for producing a bevel of a building panel according to an embodiment of the inventive concept;

[0235] Fig. 10B From another angle, it is schematically shown Fig. 10A Methods in

[0236] Fig.11 schematically shows a side view of a cross section of a building panel before the desired edge of the finished building panel is produced;

[0237] Fig. 12A Schematically illustrates step one of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0238] Fig. 12B yes Fig. 12A Detailed view of

[0239] Fig. 12C Schematically shows the Fig. 12A a side view of a cross section of the building panel after step one of;

[0240] Fig.13A Schematically illustrates step two of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0241] Fig. 13B yes Fig.13A Detailed view of

[0242] Fig.14A Schematically illustrates step three of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0243] Fig. 14B yes Fig.14A Detailed view of

[0244] Fig. 14C Shown in Fig.14A a side view of a cross section of the building panel after step three in;

[0245] Fig.15A Step four of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept is shown;

[0246] Fig. 15B yes Fig.15A Detailed view of

[0247] Fig.16A Schematically illustrating the steps of a finishing method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0248] Fig. 16B Schematically shows the Fig.16A a side view of a cross section of a building panel after the steps in;

[0249] Fig.17A Schematically showing the steps of another finishing method for producing a desired edge of a building panel according to an embodiment of the inventive concept,

[0250] Fig. 17B Schematically shows the Fig.17A a side view of a cross section of a building panel after the steps in;

[0251] Fig.18A schematically illustrating the steps of a further finishing method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0252] Fig.18B yes Fig.18A Detailed view of

[0253] Fig.18C Schematically shows the Fig.18A a side view of a cross section of a building panel after the steps in;

[0254] Fig.19A schematically shows a side view of a cross section of a building panel before producing an alternative intended edge of the finished building panel;

[0255] Fig.19B Schematically shows a method for producing a notch in an edge of a building panel according to another embodiment of the inventive concept after the steps of Fig.19A A side view of a cross section in FIG.

[0256] Fig.19C Schematically shows the Fig.19BMethod for producing a beveled surface of a building panel according to an embodiment of the inventive concept after the steps of Fig.19A A side view of a cross section in FIG.

[0257] Fig.19D Schematically shows the Fig.19C The finishing method for producing a mechanical locking device of a building panel according to an embodiment of the inventive concept after the steps of Fig.19A A side view of a cross section in FIG.

[0258] Fig. 20A Schematically illustrates step one of a method for producing a building panel from a panel stock according to an embodiment of the inventive concept;

[0259] Fig. 20B Schematically shows Fig. 20A A side view of a cross section of a panel stock plate;

[0260] Fig.21A Schematically illustrates step two of a method for producing a building panel from a panel stock according to an embodiment of the inventive concept;

[0261] Fig.21B Schematically shows Fig.21A A side view of a cross section of a panel stock plate;

[0262] Fig.22A Schematically illustrates step three of a method for producing a building panel from a panel stock according to an embodiment of the inventive concept;

[0263] Fig. 22B Schematically shows Fig.22A A side view of a cross section of a panel stock plate;

[0264] Fig.23A Schematically illustrates step four of a method for producing a building panel from a panel stock according to an embodiment of the inventive concept;

[0265] Fig. 23B Schematically shows Fig.23A A side view of a cross section of a panel stock plate;

[0266] Fig.24A Schematically illustrates step five of a method for producing a building panel from a panel stock according to an embodiment of the inventive concept;

[0267] Fig. 24B Schematically shows Fig.24A A side view of a cross section of a panel stock plate;

[0268] Fig.25 The method steps of Figures 20-24 are schematically shown;

[0269] Fig.26 is a photograph of a panel stock according to one embodiment, the panel stock having pressed grooves obtained by a method according to an embodiment of the inventive concept;

[0270] Fig.27A According to one embodiment, two building panels are connected, for example, by Figures 14A-14C The method shown produces a photograph following the expected edge;

[0271] Fig.27B After cutting the edge Fig.27A A photograph of two architectural panels in

[0272] Fig.27C are placed next to each other to show the assembly position Fig.27B Photo of two building panels. DETAILED DESCRIPTION

[0273] Specific embodiments of the inventive concept will now be described with reference to the accompanying drawings. However, the inventive concept can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided to make this disclosure thorough and complete and to fully convey the scope of the invention to those skilled in the art. The terms used in the detailed description of the embodiments shown in the accompanying drawings are not intended to limit the inventive concept. In the accompanying drawings, the same reference numerals represent the same elements.

[0274] Generally, in this disclosure, terms like "below" or "lower" generally mean closer to the rear surface of the panel or its plane, while "above" or "upper" mean closer to the front surface of the panel or its plane. In addition, when the panel is laid flat on a surface, the thickness direction of the panel is defined as the vertical direction. When the building panel is laid flat on, for example, a floor, the horizontal direction and the vertical direction are applicable definitions. In addition to the horizontal direction and the vertical direction, the description will also refer to the direction parallel to the extension of the decorative surface and the direction perpendicular to the extension of the decorative surface. When the building panel is laid flat on, for example, a floor, the horizontal direction is the same as the direction parallel to the extension of the decorative surface, and the vertical direction is the same as the direction perpendicular to the extension of the decorative surface.

[0275] In the present disclosure, plastically deformable sublayers are shown and discussed. The definition of a plastically deformable layer used throughout the present disclosure refers to a layer in which the shape of the layer can be changed under the application of heat and pressure, and the changed shape can be maintained during and after the application of heat and pressure. For example, by applying heat and pressure, bevels, depressions and / or protrusions can be formed in the material of the plastically deformable layer, and the bevels, depressions and / or protrusions can be maintained during and after the application of heat and pressure. The plastically deformable layer can be considered to be fully plastically deformable when an embossed plate having grooves with a depth of 1.2 mm and a bottom width of 2 mm is pressed on the layer for 35 seconds at a pressure of 20 bars and a temperature of 80°C to form a 0.04 mm depression. In a further embodiment, the plastically deformable layer may be considered to be sufficiently plastically deformable when an embossing plate having grooves with a depth of 1.2 mm and a bottom width of 2 mm is pressed onto the layer at a pressure of 20 bar and a temperature of 80°C for 35 seconds to form a depression of, for example, 0.06 mm, such as 0.08 mm, such as 0.1 mm, such as 0.12 mm.

[0276] In other embodiments, the plastically deformable layer may be considered to be fully plastically deformable when the plastically deformable layer is more plastically deformable than the substrate. That is, when each of the plastically deformable layer and the substrate is pressed for 35 seconds at a pressure of 20 bar and a temperature of 80° C. with an embossed plate having grooves with a depth of 1.2 mm and a bottom width of 2 mm, the depression formed in the plastically deformable layer is deeper than the depression formed in the substrate. For example, when each of the plastically deformable layer and the substrate is pressed for 35 seconds at a pressure of 20 bar and a temperature of 80° C. with an embossed plate having grooves with a depth of 1.2 mm and a bottom width of 2 mm, the depression in the plastically deformable layer may be at least 10% deeper, such as at least 25% deeper, such as at least 50% deeper, than the depression formed in the substrate.

[0277] The purpose of making the sub-layer plastically deformable is to allow easier and / or deeper beveling and / or embossing of the building panel during the manufacturing process without affecting the substrate or at least with less impact. Thus, one advantage of the plastically deformable sub-layer is that the substrate can be protected from the pressure of embossing during the manufacturing process, if necessary.

[0278] Figure 1A and Figure 1B is a schematic diagram of two different types of building panels 1 having a rectangular shape. Each building panel 1 has a substrate 3 , a sublayer 5 and a surface layer 7 .

[0279] The substrate 3 is arranged at the back side of the building panels 1 . The lower side of the substrate 3 forms the rear surface 4 of the building panels 1 , the upper side of the substrate 3 is attached to a sublayer 5 of the building panels 1 . Figure 1A The building panel 1 in the embodiment has a single-layer substrate 3, and Figure 1BThe building panel 1 in has a multilayer substrate 3. The multilayer substrate 3 may comprise two or more layers forming the substrate 3, such as a backing layer, a balancing layer, a reinforcement layer, a mineral based layer or a sound insulation layer.

[0280] The sublayer 5 is arranged between the substrate 3 and the surface layer 7. The sublayer 5 is configured to be plastically deformable when at least pressure, and preferably also heat, is applied to the sublayer 5 and / or the surface layer 7. This is advantageous when a bevel 10 is formed at the edge 15, 16, 17, 18 of the building panel 1, for example by pressing or by pressing and heating, or a groove 11 is formed in the panel stock 2. The methods of forming the pressed bevel 10 and the pressed groove 11, respectively, are described in more detail below.

[0281] Substrate 3 includes substrate material, and the substrate material includes polymer-based material, and the polymer-based material is preferably a thermoplastic material. Thermoplastic material can be selected from the group including the following materials: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene-vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or its combination. The substrate material may include at least 10wt%, at least 15wt% or at least 20wt% of the thermoplastic material. For example, the sublayer material may include 10-95wt%, 15-85wt% or 20-70wt% of the polymer-based material such as thermoplastic material.

[0282] The substrate material preferably has less than 10 wt% wood-based material, or less than 5 wt% wood-based material, such as 0.5-10 wt% wood-based material. The wood-based material may be, for example, wood fibres or wood chips.

[0283] The substrate material may also include at least one or more of an organic filler, an inorganic filler, and a combination thereof. Examples of organic fillers are rice husks and fibers of bamboo or coconut. These types of organic fillers are generally low cost and readily available. The substrate may include 1-70 wt % of an organic filler, or 30-70 wt % of an organic filler. Examples of inorganic fillers are calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, and / or a combination thereof. These types of fillers are particularly cost effective and readily available.

[0284] The substrate material may also contain a plasticizer selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The substrate material forming the substrate may include the plasticizer in an amount of 1-30 wt % or 2-15 wt %.

[0285] Typical SPC substrates that can be preferably used for such applications may contain 10-40wt%, 15-35wt%, or 20-30wt% of thermoplastic materials, such as PVC. The SPC core may also contain 50-90wt%, 60-80wt%, or 65-75wt% of inorganic fillers, such as chalk. The SPC core may also contain 0-20wt%, 1-15wt%, or 2-10wt% of additives, such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0286] A typical LVT substrate that may also be preferred for this type of application will have a material content similar to that of the SPC substrate described above, i.e., 10-40wt%, 15-35wt% or 20-30wt% thermoplastic material, 50-90wt%, 60-80wt% or 65-75wt% inorganic filler and 0-20wt%, 1-15wt% or 2-10wt% additives, but with 1-20wt%, 2-15wt% or 3-10wt% plasticizer added.

[0287] Sublayer 5 comprises a sublayer material, which comprises a polymer-based material, preferably a thermoplastic material. The thermoplastic material of the sublayer material can be selected from the group consisting of polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene-vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0288] The sub-layer material may comprise at least 10 wt%, at least 15 wt% or at least 20 wt% of a polymer-based material, such as a thermoplastic material.

[0289] The sub-layer material may comprise a polymer-based material such as a thermoplastic material in an amount of 10-95 wt%, 15-85 wt%, or 20-70 wt%.

[0290] As mentioned above, the sub-layer material is a polymer based material and comprises less than 10 wt% wood based material, or even less than 5 wt% wood based material, such as 0.5-10 wt% wood based material.

[0291] The sublayer material may also include one or more fillers, which are at least one or more of an organic filler, an inorganic filler, and a combination thereof. Fillers have advantages such as improved layer properties and cost effectiveness. Examples of organic fillers are fibers of bamboo or coconut, wood flour, and rice husks. These types of organic fillers are generally low cost and readily available. The sublayer may include 1-70wt% of an organic filler, or 30-70wt% of an organic filler. Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or a combination thereof. These types of fillers are particularly cost-effective and readily available.

[0292] In case the sub-layer material comprises a mineral based filler, in particular if it is calcium carbonate (CaCO3), the sub-layer material may comprise such filler in an amount of 1-80 wt%.

[0293] In addition, the sublayer material may contain plastisol. Plastisol gives the sublayer soft and durable properties. Plastisol is a composition of PVC particles suspended in a plasticizer. Plastisol may also contain usually small amounts of extenders, stabilizers, pigments and / or fillers. The weight ratio between PVC particles and plasticizer is preferably 50 / 50. In one embodiment, the sublayer material consists of plastisol.

[0294] To form at least the bevel 10 and / or the groove 11 of the building panel 1 the sublayer material is configured to at least partially plastically deform when pressure is applied. To make the sublayer material plastically deformable the material may comprise a plasticizer or comprise at least two different types of polymers as described below.

[0295] If the sub-layer material contains a plasticizer, it can be selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The sub-layer material forming the sub-layer comprises a plasticizer in an amount of 1-30 wt% or 2-15 wt%. The plasticizer provides the sub-layer with the desired formability characteristics.

[0296] As an alternative to plasticizers, the sub-layer material may include at least two different types of polymers. For example, the sub-layer material may include a material blend containing a PVC / PVAc copolymer, wherein the PVAc content in the sub-layer material blend is 1-20wt%, and the PVC content in the material blend may be 80-99wt%.

[0297] The sub-layer 5 produced from the sub-layer material preferably has a thickness of 0.1-2 mm, a thickness of 0.2-1 mm or a thickness of 0.3-1 mm.

[0298] The density of the sublayer can be 1.0g / cm 3 Up to 2.5g / cm 3 For example, if the sublayer comprises plastisol, the density of the sublayer can be as low as 1.0-1.4 g / cm 3 .

[0299] The sublayer may be foamed. The sublayer may be foamed and have a density reduction of at least 10%, at least 20% or at least 30% compared to a non-foamed sublayer of the same sublayer material. One advantage of a foamed sublayer is that it reduces the weight of the layer. In addition, the foamed sublayer material may not rebound to the same extent as a non-foamed sublayer material after forming, for example, a ramp.

[0300] The surface layer 7 is arranged on the sub-layer 5 above the sub-layer 5. The upper side of the surface layer 5 forms the front surface 8 of the building panel 1. The surface layer 7 may be a single-layer surface layer or may be a multi-layer surface layer comprising two or more layers. Preferably, the surface layer 5 comprises at least a decorative layer and a wear layer, wherein the decorative layer is arranged between the sub-layer 5 and the wear layer, and the wear layer is the uppermost layer of the building panel 1.

[0301] The decorative layer can be a colored powder layer, paper, polymer-based board, wood-based board, wood veneer layer, cork-based board or fabric (woven fabric or non-woven fabric). The decorative layer can also be a printed layer, such as a printed polymer-based board.

[0302] The wear-resistant layer may be a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a paint layer. The wear-resistant layer is preferably a transparent layer, ie a layer which does not affect the appearance of the decorative layer arranged below.

[0303] A coating (not shown) may be applied over the wear layer, forming the uppermost layer of the building panel 1 , if applied.

[0304] Figure 2 is a top view of a building panel 1 which is configured to be locked horizontally and / or vertically to similar or substantially identical building panels 1 ', 1 " during assembly.

[0305] Figure 2 The building panels in FIG. 1 are shown as having a rectangular / cuboid shape, but may have different shapes in other embodiments. Figure 2The shown building panel 1 comprises four edges, a first edge 15, a second edge 16, a third edge 17 and a fourth edge 18. The first edge 15 is arranged opposite the second edge 16 and the third edge 17 is arranged opposite the fourth edge 18.

[0306] Front surface 8 and rear surface 4 each extend between first edge 15 and opposite second edge 16, and between third edge 17 and opposite fourth edge 18. Rear surface 4 is substantially parallel to front surface 8 and spaced apart in a direction perpendicular thereto.

[0307] As mentioned above, the building panel 1 comprises a bevel 10 arranged in the upper part 20 of the building panel 1 at least along the first and second edges 15, 16, i.e. the long sides of the building panel 1 having a rectangular shape. It may not always be desirable to have bevels along the short sides of the rectangular building panel, but this is of course an optional arrangement to include bevels along the short sides, just as bevels 10 along the long sides of the building panel 1. The building panel 1 may be provided with bevels 10 along both long and short sides, only along long sides, only along short sides, only along one long side, only along one short side or only along one long side and one short side.

[0308] The upper part 20 is located at the front side of the building panel 1 and may comprise the surface layer 7 and at least part of the sub-layer 5 .

[0309] If desired, the bevel 10 can also be arranged along the third and fourth edges. The bevel 10 can extend along the entire extension length of the edges 15, 16 on which the bevel 10 is arranged. A schematic diagram of the bevel 10 can be seen in Figures 4A-6C The bevel 10 may extend into the surface layer 7 and at least partially into the sublayer 5 in a direction substantially perpendicular to the front surface 8 .

[0310] Furthermore, the building panel 1 may comprise at least one type of mechanical locking means 100, 100', which is configured to lock similar or substantially identical building panels 1, 1', 1" in an assembled position. Such mechanical locking means 100, 10' are configured to lock the building panels 1, 1', 1" in a vertical and / or horizontal direction, which may also be referred to as directions perpendicular and / or parallel to the rear or front surface 4, 8.

[0311] In the embodiment shown, the building panels 1 are provided with two types of mechanical locking means, first mechanical locking means 100 being arranged along the first and second edges 15, 16 and second mechanical locking means 100' being arranged along the third and fourth edges 17, 18. The first mechanical locking means 100 are designed such that the first edge 15 of the building panel 1 is configured to be assembled and locked to the second edge 16 of an adjacent building panel 1', 1", and the second edge 16 of the building panel 1 is configured to be assembled and locked to the first edge 15 of another adjacent building panel 1', 1", since the building panels are similar or substantially identical. The same applies to the second mechanical locking means 100', wherein the third edge 17 of the building panel 1 is configured to be assembled and locked to the fourth edge 18 of an adjacent building panel 1', 1", and the fourth edge 18 of the building panel 1 is configured to be assembled and locked to the third edge 17 of another adjacent building panel 1', 1". Hence, the opposing edges of the building panels 1 are designed to be compatible with each other.

[0312] The first mechanical locking device 100 is implemented in Figures 4A-4C and 6A-6C. Figures 5A-5C An embodiment of a second mechanical locking device 100 ′ is shown.

[0313] The assembly process of a plurality of building panels 1, 1', 1" is Figure 3A and Figure 3B , in which a group of building panels 1, 1', 1" such as floor panels, wall panels, ceiling panels, furniture elements or the like are assembled to each other. The building panels 1 are assembled by first arranging a first edge 15 of a building panel 1 in a second edge 16 of an adjacent building panel 1'. The building panels 1 can preferably be displaced in a direction of extension along the second edges 16 of adjacent building panels 1'. After the building panels 1 have been displaced into their desired position, the first edge 15 of the building panel 1 is locked into the second edge 16 of the adjacent building panel 1' by a folding displacement F, while a third edge 17 of the building panel is assembled and locked to a fourth edge 18 of another adjacent building panel 1". The building panel 1 is folded downwards so that the second edge 16 of the building panel 1 is displaced relative to the first edge 15 in a direction perpendicular to the front surface 8. The mechanical locking means 100' arranged along the third edge 17 and the fourth edge 18 are configured to continuously assemble and lock the adjacent third edge 17 and fourth edge 18 throughout the folding displacement F of the building panel 1.

[0314] Figure 4A , 4B4C show cross sections of two opposite edges 15, 16 of two adjacent building panels 1, 1' provided with a first mechanical locking device 100 in an unassembled position, an assembled position and a position during assembly. The two adjacent building panels 1, 1' are assembled by folding displacement as described above and locked together by the mechanical locking device 100. This type of mechanical locking device is particularly advantageous for use along the long sides of rectangular building panels.

[0315] The mechanical locking device 100 is provided at a first edge 15 of a building panel 1 with a locking tongue 21 extending from the first edge 15. The locking tongue 21 is configured to be received in a tongue groove 31 provided in a second edge 16 of an adjacent building panel 1'. The locking tongue 21 and the tongue groove 31 are configured to lock the two adjacent building panels 1, 1' at least in a direction perpendicular to the front surface 8. In the assembled position, an upper surface 22 of the locking tongue 21 cooperates with or even contacts an upper surface 32 of the tongue groove 31, wherein the two surfaces 22, 32 form a lock at least in a direction perpendicular to the front surface 8.

[0316] Below the upper surface 32 of the tongue and groove 31, seen from the front surface 8, a locking strip 34 is provided which extends from the second edge 16 of the adjacent building panel 1 '. At the outermost end of the locking strip 34, a locking element 36 is provided. The locking element 36 is configured to be received in a locking groove 24 provided at the first edge 15 of the building panel 1. The locking element 36 and the locking groove 24 are configured to lock two adjacent building panels 1, 1 ' at least in a direction parallel to the front surface 8. In the assembled position, the locking surface 25 of the locking groove 24 cooperates or even contacts with the locking surface 37 of the locking element 36, wherein the two locking surfaces 25, 37 produce a locking at least in a direction parallel to the front surface 8.

[0317] In the upper part 20, 20' of each building panel 1, 1', two further locking surfaces 28, 38 are provided. In the assembled position, the locking surfaces 28, 38 are arranged opposite each other, cooperating with each other or even contacting each other so as to lock two adjacent building panels 1, 1' in a direction parallel to the front surface 8. Preferably, the two locking surfaces 28, 38 create a tight seal in the assembled position. A tight seal has several advantages, such as reducing the risk of dust or fluids entering downwards into the mechanical locking device 100 and damaging the building panels 1, 1', or for example creating a desired transition between two adjacent building panels 1, 1', wherein the bevel 10 is also advantageous. Creating a desired transition between adjacent building panels 1, 1' may be particularly desirable if the decorative layer of the surface layer 7 is a printed layer of any material, since the printed layer can then transition into the adjacent printed layer without gaps, which might interrupt the decorative surface. When a plurality of building panels 1, 1', 1" are assembled to form a panel component board, such as a floor, a wall, etc., interruptions in the decorative surface may create an undesirable surface decoration.

[0318] The two locking surfaces 28, 38 extend in a direction substantially perpendicular to the front surface 8. The two locking surfaces 28, 38 are the uppermost pair of locking surfaces of two adjacent building panels 1, 1 ' in assembled position.

[0319] Figure 5A , 5B and 5C show cross-sections of two adjacent building panels 1, 1" in an unassembled position, an assembled position and a position during assembly, of two opposite edges 17, 18 provided with a second mechanical locking device 100'. As described above, two adjacent building panels 1, 1" are assembled by folding displacement and continuous vertical displacement of the second edge 16 relative to the first edge 15 and locked together by the mechanical locking device 100'. This type of mechanical locking device may be particularly advantageous for use along the short sides of rectangular building panels or for square tiles.

[0320] The mechanical locking device 100' is provided with a locking tongue 41 at the third edge 17 of the building panel 1, which is provided with a tongue groove 42. The tongue groove 42 is configured to receive a displaceable locking tongue 51 in the assembled position, the locking tongue 51 being arranged in a displaceable tongue receiving groove 52 in the fourth edge 18 of an adjacent building panel 1". The displaceable locking tongue 51 and the tongue groove 42 are configured to lock two adjacent building panels 1, 1" at least in a direction perpendicular to the front surface 8.

[0321] The displaceable locking tongue 51 can be separated from the rest of the mechanical locking device 100' and arranged in the displaceable tongue receiving groove 52, e.g. by hand or by machine, before or during assembly of the building panels 1, 1', 1". Figure 5CThe displaceable locking tongue 51 is configured to be displaced in the displaceable tongue receiving groove 52 by being at least partially flexible when the locking tongue 41 at the third edge of the building panel 1 is displaced downwards towards the assembly position in a direction perpendicular to the front surface 8. When the displaceable locking tongue 51 reaches the tongue groove 42, it snaps into the locked position, see Figure 5B , and locks two adjacent building panels 1, 1". in a direction at least perpendicular to the front surface 8. In the assembled position, the lower locking surface 43 of the tongue groove 42 cooperates with or even contacts the lower locking surface 53 of the displaceable locking tongue 51, wherein the two locking surfaces 43, 53 form a locking of the assembled panels 1, 1" at least in a direction perpendicular to the front surface 8.

[0322] Seen from the front surface 8, below the displaceable tongue receiving groove 52, a locking strip 54 is provided which extends from the fourth edge 18 of the adjacent building panel 1". At the outermost end of the locking strip 54, a locking element 56 is provided. The locking element 56 is configured to be received in a locking groove 44 provided at a third edge 17 of the building panel 1. The locking element 56 and the locking groove 44 are configured to lock two adjacent building panels 1, 1". In the assembled position, the locking surface 45 of the locking groove 44 cooperates or even contacts with the locking surface 57 of the locking element 56, wherein the two locking surfaces 45, 57 produce a locking at least in a direction parallel to the front surface 8.

[0323] In the upper part 20, 20" of each building panel 1, 1", two further locking surfaces 48, 58 are provided. In the assembled position, the locking surfaces 48, 58 are arranged opposite each other, cooperate with each other or even contact each other so as to lock two adjacent building panels 1, 1". Preferably, the two locking surfaces 48, 58 create a tight seal in the assembled position. A tight seal has several advantages, such as reducing the risk of dust or fluids getting down into the mechanical locking device 100' and damaging the building panels 1, 1', or for example creating a desired transition between two adjacent building panels 1, 1", wherein the optional bevel 10 is also advantageous. Creating a desired transition between adjacent building panels 1, 1" may be particularly desirable if the decorative layer of the surface layer 7 is a printed layer of any material, as the printed layer can then transition into the adjacent printed layer without gaps, which could interrupt the decorative surface. When a plurality of building panels 1, 1', 1" are assembled to form a panel component board, such as a floor, wall, etc., interruptions in the decorative surface may create an undesirable surface decoration.

[0324] The two locking surfaces 48, 58 extend in a direction substantially perpendicular to the front surface 8. In the assembled position the two locking surfaces 48, 58 are the uppermost pair of locking surfaces of two adjacent building panels 1, 1".

[0325] Fig. 6A , Figure 6B and Figure 6C A cross section of two opposing edges 15, 16 of two adjacent building panels 1, 1' provided with an alternative first mechanical locking device 100 is shown in an unassembled position, an assembled position and a position during assembly. With this alternative mechanical locking device 100, two adjacent building panels 1, 1' are assembled by a vertical displacement of a building panel 1 relative to an adjacent building panel 1' instead of a folding displacement. The mechanical locking device 100 is provided with a locking tongue 21 with a ridge 23 at a first edge 15 of the building panel 1. The ridge 23 is configured to receive an upper surface 32 of a tongue groove 31 provided in a second edge 16 of the adjacent building panel 1'. The ridge 23 and the upper surface 32 of the tongue groove 31 are configured to lock the two adjacent building panels 1, 1' at least in a direction perpendicular to the front surface 8. When the ridge 23 reaches the upper surface 32 of the tongue groove 31, it snaps into the locked position, see Figure 6B , and locks two adjacent building panels 1 , 1 ′ at least in a direction perpendicular to the front surface 8.

[0326] In the assembled position, the ridge 23 of the locking tongue 21 cooperates with or even contacts the upper surface 32 of the tongue groove 31 , thereby producing a locking at least in a direction perpendicular to the front surface 8 .

[0327] Below the upper surface 32 of the tongue and groove 31, seen from the front surface 8, a locking strip 34 is provided which extends from the second edge 16 of the adjacent building panel 1 '. At the outermost end of the locking strip 34, a locking element 36 is provided. The locking element 36 is configured to be received in a locking groove 24 provided at the first edge 15 of the building panel 1. The locking element 36 and the locking groove 24 are configured to lock two adjacent building panels 1, 1 ' at least in a direction parallel to the front surface 8. In the assembled position, the locking surface 25 of the locking groove 24 cooperates or even contacts with the locking surface 37 of the locking element 36, wherein the two locking surfaces 25, 37 produce a locking at least in a direction parallel to the front surface 8.

[0328] In the upper part 20, 20' of each building panel 1, 1', two further locking surfaces 28, 38 are provided. In the assembled position, the locking surfaces 28, 38 are arranged opposite each other, cooperating with each other or even contacting each other in order to lock two adjacent building panels 1, 1' in a direction parallel to the front surface 8. Preferably, the two locking surfaces 28, 38 create a tight seal in the assembled position. A tight seal has several advantages, such as reducing the risk of dust or fluids getting down into the mechanical locking device 100 and damaging the building panels 1, 1', or for example creating a desired transition between two adjacent building panels 1, 1', wherein the bevel 10 is also advantageous. Creating a desired transition between adjacent building panels 1, 1' may be particularly desirable if the decorative layer of the surface layer 7 is a printed layer of any material, since the printed layer may then transition into the adjacent printed layer without gaps, which might interrupt the decorative surface. When a plurality of building panels 1, 1', 1" are assembled to form a panel component (eg a floor, a wall etc.), interruptions in the decorative surface may result in an undesirable surface decoration.

[0329] The two locking surfaces 28, 38 extend in a direction substantially perpendicular to the front surface 8. The two locking surfaces 28, 38 are the uppermost pair of locking surfaces of two adjacent building panels 1, 1 ' in assembled position.

[0330] Having a pressing bevel 10 as described herein and in combination with Figures 5A-5C An advantage of the mechanical locking device 100 shown in Figures 6A-6C, in which the building panels 1, 1', 1" are assembled by a substantially vertical displacement, is that the bevel 10 can serve as a guiding surface for the inclined surfaces 27, 47 of the locking tongues 21, 41. This may happen in case the building panels 1 to be assembled are arranged to slightly overlap the adjacent building panels 1', 1". The pressed bevel 10 with its seamless surface can then provide a smooth lateral movement of the building panels 1 so that the building panels 1 to be assembled are displaced on / into the correct position.

[0331] Fig. 7A and Figure 7B Schematically shown is a possible method of manufacturing a building panel 1 or a panel blank 2 from which a plurality of building panels 1 can be extracted by eg a cutting process.

[0332] Step one is to combine the substrate material and the sublayer material to form the substrate 3 and the sublayer 5 of the building panel 1 or panel stock 2. Fig. 7AAs shown, the substrate material and the sub-layer material may be bonded together by heat and pressure using a first single press device 61. The first single press device 61 is preferably a continuous press device 61 through which the substrate material and the sub-layer material are fed at a constant speed along a feed direction F. Typical speeds through the continuous press device 61 are in the range of 10 meters / minute (m / min) to 40 m / min, preferably about 30 m / min.

[0333] In the example shown, the substrate material is a single-layer material, forming a single-layer substrate 3 of the building panel 1 or panel stock 2. The substrate material comprises a polymer-based material, which is preferably a thermoplastic material. The thermoplastic material may be selected from the group comprising: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0334] The substrate material may comprise a polymer-based material, such as a thermoplastic material, in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0335] The substrate material may preferably contain less than 10 wt % of wood-based materials, or less than 5 wt % of wood-based materials.

[0336] The substrate material may also include at least one or more of an organic filler, an inorganic filler, and a combination thereof. Examples of organic fillers are fibers of bamboo or coconut and rice husks. These types of organic fillers are generally low cost and readily available. The substrate may include 1-70 wt % of an organic filler, or 30-70 wt % of an organic filler. Examples of inorganic fillers are calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, and / or a combination thereof. These types of fillers are particularly cost effective and readily available.

[0337] The substrate may also contain a plasticizer. The plasticizer may be selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The substrate material forming the substrate may contain 1-30 wt % or 2-15 wt % of a plasticizer.

[0338] Typical SPC substrates that can be preferably used for such applications may contain 10-40wt%, 15-35wt%, or 20-30wt% of thermoplastic materials, such as PVC. The SPC core may also contain 50-90wt%, 60-80wt%, or 65-75wt% of inorganic fillers, such as chalk. The SPC core may also contain 0-20wt%, 1-15wt%, or 2-10wt% of additives, such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0339] A typical LVT substrate that may also be preferably used for this type of application will have a material content similar to that of the SPC substrate described above, i.e., 10-40wt%, 15-35wt% or 20-30wt% of thermoplastic material, 50-90wt%, 60-80wt% or 65-75wt% of inorganic filler and 0-20wt%, 1-15wt% or 2-10wt% of additives, but with 1-20wt%, 2-15wt% of plasticizer added.

[0340] The sublayer material produces a sublayer 5 of the building panel 1 or the panel stock 2 and comprises a polymer-based material, preferably a thermoplastic material. The thermoplastic material of the sublayer material may be selected from the group comprising polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0341] The sub-layer material may comprise at least 10 wt%, at least 15 wt% or at least 20 wt% of a polymer-based material, such as a thermoplastic material.

[0342] As mentioned above, the sub-layer material is a polymer based material.The sub-layer material may comprise less than 10 wt% wood based material, or even less than 5 wt% wood based material.

[0343] The sublayer material may also include one or more fillers, which are at least one or more of an organic filler, an inorganic filler, and a combination thereof. Fillers have advantages such as improved layer properties and cost effectiveness. Examples of organic fillers are bamboo or coconut fibers, wood flour, and rice husks. These types of organic fillers are generally low cost and readily available. The sublayer may include 1-70wt% of an organic filler, or 30-70wt% of an organic filler. Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or a combination thereof. These types of fillers are particularly cost-effective and readily available.

[0344] In case the sub-layer material is a mineral based filler, in particular if it is calcium carbonate (CaCO3), it contains 1-80 wt% of this filler.

[0345] In addition, the sublayer material may contain plastisol. Plastisol gives the sublayer soft and durable properties. Plastisol is a composition of PVC particles suspended in a plasticizer. Plastisol may also contain usually small amounts of extenders, stabilizers, pigments and / or fillers. The weight ratio between PVC particles and plasticizer is preferably 50 / 50. In one embodiment, the sublayer material consists of plastisol.

[0346] To form at least the bevel 10 of the building panel 1 or the groove 11 of the panel stock 2, the sublayer material is configured to at least partially plastically deform when pressure is applied. To make the sublayer material plastically deformable, the material may contain a plasticizer or contain at least two different types of polymers, as described below.

[0347] If the sub-layer material contains a plasticizer, it can be selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances, such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The sub-layer material forming the sub-layer comprises a plasticizer in an amount of 1-30 wt% or 2-15 wt%. The plasticizer provides the sub-layer with the desired formability characteristics.

[0348] As an alternative to plasticizers, the sub-layer material comprises at least two different types of polymers. For example, the sub-layer material may comprise a material blend comprising a PVC / PVAc copolymer, wherein the PVAc content in the sub-layer material blend is 1-20wt%, and the PVC content in the material blend may be 80-99wt%.

[0349] The sub-layer 5 produced from the sub-layer material preferably has a thickness of 0.1-2 mm, a thickness of 0.2-1 mm or a thickness of 0.3-1 mm.

[0350] The density of the sublayer can be 1.0g / cm 3 Up to 2.5g / cm 3 For example, if the sublayer comprises plastisol, the density of the sublayer can be as low as 1.0-1.4 g / cm 3 .

[0351] The sublayer may be foamed. The sublayer may be foamed and have a density reduction of at least 10%, at least 20% or at least 30% compared to a non-foamed sublayer of the same sublayer material. One advantage of a foamed sublayer is that it reduces the weight of the layer. In addition, the foamed sublayer material may not rebound to the same extent as a non-foamed sublayer material after forming, for example, a ramp.

[0352] Step two is to apply the surface layer 7 to the sublayer 5 and again apply at least pressure, but preferably also heat, to form a building panel 1 or panel blank 2. The pressure applied may be in the range of 5 bar to 20 bar and the temperature applied may be in the range of 120° C. to 160° C. The pressure and preferably the heat are achieved by a second single pressing device 62, such as Figure 7B The second single press device 62 is preferably a continuous press device 62, through which the substrate, the sublayer and the surface layer are fed at a constant speed along the feed direction F. The feeding speed of the layer through the second press device 62 can be the same as the feeding speed of the material through the first single press device 61, i.e. in the range of 10 m / min to 40 m / min, preferably about 30 m / min.

[0353] The surface layer 7 comprises a decorative layer 11. The decorative layer can be a colored powder layer, paper, a polymer-based board, a wood-based board, a wood veneer layer, a cork-based board or a fabric (woven fabric or non-woven fabric). The decorative layer can also be a printed polymer-based board.

[0354] Furthermore, the surface layer 7 comprises a wear-resistant layer, for example a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a lacquer layer and / or a coating.

[0355] Fig. 8A and 8B Another possible method of manufacturing a building panel 1 or a panel blank 2 is schematically shown, from which a plurality of building panels 1 can be taken, for example by a cutting process.

[0356] Similar to Fig. 7A and 7B The method described in step 1 is to combine the substrate material and the sublayer material to form the substrate 3 and the sublayer 5 of the building panel 1 or the panel original board 2. Fig. 8A As shown, the substrate material and the sub-layer material may be bonded together by heat and pressure using a first dual press 64. The first dual press 64 is preferably a continuous press 64 through which the substrate material and the sub-layer material are fed at a constant speed along a feed direction F. As previously mentioned, a typical speed is in the range of 10 m / min to 40 m / min, preferably about 30 m / min. The applied pressure may be in the range of 5 bar to 20 bar, and the applied temperature may be in the range of 120° C. to 160° C.

[0357] In this shown example, the substrate material is a multilayer material, forming a multilayer substrate 3 of a building panel 1 or panel stock 2. The multilayer substrate material may comprise, for example, one or more of a backing layer, a balancing layer, a reinforcement layer, a mineral base layer or an acoustic insulation layer.

[0358] The substrate material comprises a polymer-based material, which is preferably a thermoplastic material. The thermoplastic material can be selected from the group consisting of polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene-vinyl acetate (EVA), polyacrylate methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0359] The substrate material may comprise a polymer-based material, such as a thermoplastic material, in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0360] The substrate material may preferably have less than 10 wt % wood-based materials, or less than 5 wt % wood-based materials.

[0361] The substrate material also includes at least one or more of an organic filler, an inorganic filler, and a combination thereof. Examples of organic fillers are coconut or bamboo fibers and rice husks. These types of organic fillers are generally low cost and readily available. The substrate may contain 1-70 wt % of an organic filler, or 30-70 wt % of an organic filler. Examples of inorganic fillers are calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, and / or a combination thereof. These types of fillers are particularly cost effective and readily available.

[0362] The substrate may further comprise a plasticizer selected from any one of the group consisting of phthalates, terephthalates, aliphatics, cyclohexanoates, adipates, trimellitates, polyol esters and other substances such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM or The substrate material forming the substrate may contain 1-30 wt % or 2-15 wt % of a plasticizer.

[0363] Typical SPC substrates that can be preferably used for such applications may contain 10-40wt%, 15-35wt%, or 20-30wt% of thermoplastic materials, such as PVC. The SPC core may also contain 50-90wt%, 60-80wt%, or 65-75wt% of inorganic fillers, such as chalk. The SPC core may also contain 0-20wt%, 1-15wt%, or 2-10wt% of additives, such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0364] A typical LVT substrate that may also be preferably used for this type of application will have a material content similar to that of the SPC substrate described above, i.e., 10-40wt%, 15-35wt% or 20-30wt% of thermoplastic material, 50-90wt%, 60-80wt% or 65-75wt% of inorganic filler and 0-20wt%, 1-15wt% or 2-10wt% of additives, but with 1-20wt%, 2-15wt% of plasticizer added.

[0365] The sub-layer materials for producing the sub-layer 5 of the building panel 1 or the panel blank 2 can be the same as described above in terms of possible contents and amounts. Fig. 7A and 7B The preferred thickness of the sub-layer 5 may also be the same as above.

[0366] Step two is to apply the surface layer 7 to the sub-layer 5, as in the previously described method, and again apply at least pressure, but preferably also heat, in order to form a building panel 1 or panel blank 2. Figure 8B As shown, pressure and preferably heat are achieved by a second double press 65. The second double press 65 is preferably a continuous double press 65, by which the substrate 3, the sublayer 5 and the surface layer 7 are fed at a constant speed in a feed direction F. The speed at which the layers are fed by the second press 65 can be the same as the speed at which the material is fed by the first press 64. As mentioned before, typical speeds are in the range of 10 m / min to 40 m / min, preferably about 30 m / min.

[0367] As mentioned above, the surface layer 7 comprises a decorative layer 11. The decorative layer can be a colored powder layer, paper, a polymer-based board, a wood-based board, a wood veneer layer, a cork-based board or a fabric (woven fabric or non-woven fabric). The decorative layer can also be a printed polymer-based board.

[0368] Furthermore, as mentioned above, the surface layer 7 may comprise a wear-resistant layer, such as a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a paint layer and / or a coating.

[0369] Fig. 9An alternative method is shown, where different materials, i.e. substrate material and sub-layer materials, are produced in an extrusion process 66 and fed through a calendaring process 67 for forming a building panel 1 or a panel precursor 2. A surface layer 7 may be applied before the calendaring process 67 for forming a building panel 1 or a panel precursor 2. The extrusion process 66 enables one or more materials to be extruded into a single-layer panel or a multi-layer panel.

[0370] Fig. 10A and 10B Different views of one possible arrangement of a process for forming a bevel 10 along two opposite edges 15, 16 of a building panel 1 are shown, in the example shown the long edge being formed with the bevel 10. The building panels 1 are conveyed on a conveyor belt 71 in a feed direction F. The building panels 1 which have previously been formed to their desired proportions may be conveyed through a heating process 73. If necessary, the heating process 73 is configured to heat an area along each edge of the building panel 1 in order to be able to form the bevel 10 at a later stage.

[0371] In an alternative arrangement of the beveling process (not shown), the heating process may be excluded and the building panels are transferred directly from the heat and pressure process performed when forming the building panels to the beveling process. In this arrangement, the heat used when forming the building panels is used for forming the bevel, i.e. the area along the edge of the building panel is still hot enough for the beveling process.

[0372] In another alternative arrangement of the bevel forming process (not shown), the heating process may be included in the bevel forming process, ie the two processes are not separate processes but are combined with the bevel forming process to form a combined heating and bevel forming process.

[0373] Therefore, there are various possible arrangements for the manufacturing process, for example, the bevel 10 can be formed simultaneously when the building panel is formed by heat and pressure (described below), or the bevel 10 can be formed in a process after the process of forming the building panel 1, but the heat used in the process of forming the building panel 1 is sufficient for the subsequent bevel forming process, or the bevel 10 can be formed in a process after the process of forming the building panel 1, wherein the bevel forming process includes heating at least the area of ​​the building panel 1 in which the bevel is to be formed, or even the bevel forming process is performed without heating and only pressure is used to form the bevel 10.

[0374] After the heating process 73, as Fig. 10A and 10BAs shown, the building panels 1 are conveyed to a bevel forming process 75. The edges of the building panels 1 are guided into the bevel forming process 75 by guide surfaces 76. The bevel forming process 75 is configured to form the bevel 10 from above (i.e. the surface facing upwards) or from below (i.e. the surface facing downwards towards the conveyor belt 71) by pressing or shaping the surface layer 7 by means of a shaping device 77. A more detailed view of one type of bevel forming process 75 is shown in FIG. Fig.14A -C and described below.

[0375] An alternative method (not shown) to the bevel forming process described above is to press form the bevel 10 of the building panel 1 while forming the building panel itself and bonding the layers, i.e. the substrate, sub-layer and surface layer together. The at least one bevel 10 may be formed with the same pressing device as used to form the building panel. The pressing device may then preferably be provided with features, such as protrusions, for producing such a bevel.

[0376] After and near the bevel forming process 75, a cooling process 79 is arranged for cooling the bevel 10 and the area of ​​the edge where the bevel 10 has been formed. The cooling process 79 is advantageous in order to prevent undesirable elastic and / or recovery effects in the material of the bevel 10. The cooling process 79 is advantageous in maintaining the shape and proportions of the bevel 10.

[0377] The cooling process 79 is preferably an active process, so as to shorten the time compared with reducing the material temperature by the surrounding environment. The cooling process 79 can be realized by using cooling devices 87a, 87b of air, liquid, gas, solid material and / or other suitable means. The cooling device 87a, 87b can be cooled by, for example, blasting, spraying, evaporation and / or by contact. The cooling process 79 can be configured to reduce the temperature of the material in the region where the inclined surface is formed by 15% to 40%. Depending on the cooling type used by the cooling device and the temperature of this cooling, the time spent by the cooling process can vary. For example, if cold water is used, the cooling process may require 2 seconds to 20 seconds, and if cold air is used, the cooling process may require 30 seconds to 2 minutes, which all depends on the type and temperature of cooling.

[0378] Fig.11 -18 shows different possible steps for processing the edges 15, 16, 17, 18 of the building panels 1, wherein Fig.11 The building panel 1 is shown with a substrate 3, a sub-layer 5 and a surface layer 7 after being bonded together by pressure and preferably also by heating.

[0379] When the building panel 1 comprises a substrate 3 which does not deform plastically or at least does not deform plastically sufficiently, Fig.11 The arrangement of the final processing of the edges 15, 16, 17, 18 of the building panel 1 shown in -18 is particularly advantageous. Figures 19A-19D A possible arrangement for the final processing of the edges 15, 16, 17, 18 of a building panel 1 having a substrate 3 which is sufficiently plastically deformable is shown.

[0380] It is possible to form the bevel 10 along the building panel 1 directly after it has been formed by means of pressure and preferably also by means of heat, but in order to ease the formation of the bevel 10 even further a process of creating notches 81a, 81b may be performed.

[0381] exist Figures 12A-12C A possible way of producing notches 81a, 81b is shown in Fig. Notches 81a, 81b are preferably temporary features of the edge 15, 16, 17, 18 of the building panel 1 which no longer assume their original shape during the final forming process, ie the finishing process. An example of a finishing process is described below.

[0382] During this notch creation process, the building panel 1 is placed in or transported to the milling process 82, preferably by means of a conveyor belt. The building panel 1 is typically processed with its base plate 3 facing upwards and its surface layer 7 facing downwards, but in alternative embodiments it can of course be processed in the other way around, with its base plate 3 facing downwards and its surface layer 7 facing upwards.

[0383] The milling devices 83a, 83b are arranged on each side of the building panel 1. The milling devices 83a, 83b are configured to each produce a notch 81a, 81b along the edge 15, 16 of the building panel 1 in which the bevel 10 is to be formed. The milling devices 83a, 83b may also be configured to produce a notch 81, 81b of a type suitable for a mechanical locking device 100, 100' to be produced later in the edge 15, 16. The purpose of this is that the notch 81a, 81b will not affect or interfere with the proportions, shape and function of the later formed mechanical locking device 100, 100', see Figures 18A-18C .

[0384] The advantage of forming the notches 81a, 81b before forming the bevel 10 is that space is created for the material to be displaced during the pressing and forming of the bevel, reducing the risk of unwanted accumulation of excess material (which must then be removed), and reducing the tendency of the material to elastically recover and / or restore and change the properties and shape of the bevel 10.

[0385] In the example shown, each milling device 83a, 83b is configured to produce a notch 81a, 81b in the sublayer 5 mainly in an area close to the substrate 3, but in other embodiments it is also possible to produce a notch at least partially in the substrate 3 and / or the surface layer 7. The notch 81a, 81b is preferably formed in the boundary between the sublayer 5 and the substrate 3. One of the milling devices 83b is further configured to remove material from the substrate 3 in order to provide a Figures 18A-18C The contemplated mechanical locking device 100 is shown in preparation.

[0386] The notches 81a, 81b may preferably extend into the building panels 1 in a direction parallel to a plane defining the front surface 8 of the building panels 1 by the same or longer length than the intended chamfer 10 to be formed.

[0387] In case a mechanical locking device 20 is to be formed in the building panel 1 , the notch 81 , 81 b may preferably extend into the building panel in a direction parallel to a plane defining the front surface 8 of the building panel 1 in a manner not to exceed the mechanical locking device 20 , or even more preferably, to be shorter than the mechanical locking device 20 .

[0388] Preferably, the tongue 31 to be formed of the mechanical locking device 20 extends into the building panel 1 after its formation in a direction parallel to the plane defined by the front surface 8 of the building panel 1 further than the notch 81a extends. On the other side of the building panel 1, the locking groove 24 to be formed of the mechanical locking device 20 preferably extends into the building panel 1 after its formation in a direction parallel to the plane defined by the front surface 8 of the building panel 1 further than the notch 81b extends. This is preferred because the notches 81a, 81b should not affect the process of forming the mechanical locking device 20 or the dimensions of such a mechanical locking device 20. Therefore, the remaining notches are preferably removed during the formation of the mechanical locking device 20, after the bevel 10 has been formed.

[0389] In fact, whatever the final processing step along the edge of the building panels (eg finishing), after the beveling has been done, the remaining notches are preferably removed during this final processing step.

[0390] In one embodiment, the height Hi of the openings of the notches 81 a , 81 b before the bevel 10 is formed is approximately equal to the height Hb of the bevel 10 .

[0391] In another embodiment, the height Hi of the openings of the notches 81 a , 81 b before the inclined surface 10 is formed exceeds the height Hb of the inclined surface 10 .

[0392] In one embodiment, the length Li of the notch 81a , 81b into the building panel 1 in a direction parallel to the front surface 8 of the building panel 1 is approximately equal to the radius Rb of the bevel 10 .

[0393] In one embodiment, the length Li of the notch 81a , 81b into the building panel 1 in a direction parallel to the front surface 8 of the building panel 1 exceeds the radius Rb of the bevel 10 .

[0394] Creating notches as described above can be one way to mitigate / soften the ramp formation process. Another way is to have a foamed sublayer, also described above, which would allow the sublayer material to collapse in a controlled manner (not shown) when pressure is applied, i.e. the sublayer is able to change its density within the volume where the ramp is created. In an alternative process, even if the sublayer is foamed, notches as described above can still be created.

[0395] Fig.13A and 13B The next possible process is shown, which is a heating process 73, similar to the reference Fig. 10A and 10B The heating process 73 described. One heating device 85a, 85b is provided on each side of the building panel 1. Each heating device 85a, 85b is configured to heat the area in the edge of the building panel in which the bevel 10 is to be formed. Preferably, the radius of the area heated on both sides is at least 50% of the distance that the notch 81a, 81b extends from its opening into the building panel 1. The material temperature in the area or surface in which the bevel 10 is to be formed is preferably at least 40-220°C or at least 70-180°C, depending on various characteristics, such as the thickness of the material, the type of material. The heating devices 85a, 85b can use IR or UV heating, hot air, laser, ultrasound or contact heat to heat the area.

[0396] See also Figures 14A-14C After heating the area in a heating process, the bevel 10 of the building panel is formed. The bevel forming process 75 is similar to that of reference Fig. 10A and 10BThe bevel forming process 75 described. On each side of the building panel 1, a forming device 77a, 77b is provided, which is configured to form a bevel 10 in each edge of the building panel by guiding the surface layer 7 of the building panel 1 and applying pressure to the surface layer 7. The forming devices 77a, 77b are configured to form and press the surface layer 7, at least part of the sublayer 5 and sometimes even at least part of the base plate 3 upwards (because it is processed in an upside-down state). During the forming of the bevel 10, the forming devices 77a, 77b press material towards the notches 81a, 81b in the area where each bevel 10 on each side of the building panel 1 is to be formed. Therefore, the volume of the notches 81a, 81b is reduced during the bevel forming process 75. Fig. 14C The formed chamfer 10 and the reduced-volume indentations 81a, 81b are shown in FIG. Alternatively, after the chamfer 10 has been formed, the volume of the indentations 81a, 81b may be reduced to near zero, ie, have no volume.

[0397] Refer to above Figures 14A-14C The details of the bevel forming process 75 described also apply to reference Figures 10A-10B The bevel forming process 73 is described except for the notches 81a, 81b.

[0398] Fig.15A and 15B A cooling process 79 is shown, which is a preferred process step after forming the bevel 10 of the building panel 1. The cooling process 79 is similar to that described with reference to Fig. 10A and 10B A cooling process 79 is described. On each side of the building panel 1, a cooling device 87a, 87b is provided which is configured to cool the respective bevel 10 and the area in the edge of the building panel 1. The cooling process is advantageous in order to prevent undesired elasticity and / or recovery effects in the material of the bevel 10 and in order to maintain the shape and proportions of the bevel 10.

[0399] The cooling process 79 is preferably an active process in order to reduce the time compared to lowering the material temperature by the surrounding environment. The cooling process 79 can be achieved by a cooling device using air, liquid, gas, solid material and / or other suitable means. The cooling device can cool by, for example, blowing, spraying, evaporation and / or contact.

[0400] The cooling process 79 can be configured to reduce the temperature of the area of ​​the material in which the bevel is formed by 15% to 40%. Depending on the type of cooling used by the cooling device and the temperature of such cooling, the time taken for the cooling process can vary. For example, if cold water is used, the cooling process may take 2 seconds to 20 seconds, and if cold air is used, the cooling process may take 30 seconds to 2 minutes, all depending on the type and temperature of cooling.

[0401] Fig.16A and 16B , Fig.17A and 17B as well as Fig.18A and 18B Three different types of finishing processes, ie final edge shaping processes, are shown that a building panel 1 may undergo.

[0402] Fig.16A and 16B A first finishing process is shown comprising a second milling process 89 having milling devices 91a, 91b arranged on each side of the building panel 1. The milling devices 91a, 91b are configured to produce straight surfaces 92a, 92b along the edges of the building panels 1, such as Fig. 16B The surfaces 92a, 92b of the edge extend in a direction perpendicular to the front surface 8. The surfaces 92a, 92b along the edge are preferably continuous surfaces.

[0403] If the building panel 1 is processed by the first milling process and thus the notches 81a, 81b are produced, the characteristic structure of the notches (such as gaps, etc.) no longer exists after the finishing process that produces the straight surfaces 92a, 92b of the edges. In addition, the second milling process 89 is configured to produce the desired length of the bevel 10 and remove excess material from each edge of the building panel 1.

[0404] Fig.17A and 17B A second finishing process is shown, comprising an alternative second milling process 89' having milling devices 91a', 91b' arranged on each side of the building panel 1. The milling devices 91a', 91b' are configured to produce angled / inclined surfaces 92a', 92b' along the edge of the building panel 1, such as Fig. 17B The surfaces 92a', 92b' of the edge extend in an inwardly inclined direction from the front surface 8 to the rear surface 4 of the building panel 1. The surfaces 92a', 92b' along the edge are preferably continuous surfaces.

[0405] If the building panel 1 is machined by a first milling process and thereby produces notches 81a, 81b, then in one embodiment, after the finishing process of producing the inclined surfaces 92a', 92b' of the edges, the characteristic structure of the notches (e.g., gaps, etc.) no longer exists. In addition, the second milling process 89' is configured to produce a desired length of bevel 10 and remove excess material from each edge of the building panel 1.

[0406] Figures 18A-18CA third finishing process is shown, including another alternative second milling process 89". The second milling process 89" may include one or more milling devices 91a", 91b", although in Figures 18A-18C Two are shown in . The second milling process 89 ″ has milling means 91a ″, 91b ″ arranged on each side of the building panel 1 . The milling means 91a ″, 91b ″ are configured to produce mechanical locking means 100 , 100 ′ along the edge of the building panel 1 . Fig.18C One type of mechanical locking device 100 is shown. Figures 4A-6C Other possible types of mechanical locking devices 100 , 100 ′ are described. Depending on the type of mechanical locking device 100 , 100 ′ to be manufactured, one or more milling devices 91 a ″, 91 b ″ are present within the second milling process 89 ″.

[0407] If the building panel 1 is also machined by the first milling process and thereby produces notches 81a, 81b, then in one embodiment, after the finishing process that produces the mechanical locking device 100, 100', the characteristic structure of the notch (e.g., gap, etc.) no longer exists. In addition, the second milling process 89" is configured to produce a bevel 10 of a desired length and remove excess material from each edge 15, 16 of the building panel 1.

[0408] Figures 19A-19D Shown with reference Fig.11 -18 shows a cross section of a building panel 1 which is finished in a slightly different way than described. An alternative possible arrangement for the finishing of the building panel 1 is suitable when the substrate 3 is sufficiently plastically deformable under the influence of pressure and preferably also heat.

[0409] Fig.19A Shown is a cross section of a building panel 1 before final processing with a substrate 3, a sub-layer 5 and a surface layer 7 after being bonded together by pressure and preferably also by heating.

[0410] Fig.19B The building panel 1 is shown after a process of producing notches 81a, 81b. It can be seen that the notches 81a, 81b are partially or fully formed in the substrate 3. The notches 81a, 81b are produced such that their position is suitable for a subsequent intended finishing process of the edge. In this example, the subsequent intended finishing process is a process of producing mechanical locking means, and therefore the notches 81a, 81b are produced at positions that match or coordinate with the intended mechanical locking means.

[0411] To form the bevel 10, it may be necessary to sufficiently heat the area of ​​the building panel 1 between the notches 81a, 81b and the surface of the building panel in which the bevel 10 is to be formed, which in the example shown is the front surface 8 of the building panel 1. This can be achieved by any of the possible processes described above, for example by a separate heating process, by an incorporated heating process or by transferring the building panel immediately from the forming process when at least the area between the notches 81a, 81b and the surface in which the bevel 10 is to be formed is still sufficiently hot.

[0412] Fig.19C A cross section of a building panel 1 is shown after the bevel 10 has been formed and after a preferred cooling process 79. The volume of each notch 81a, 81b has been reduced because material from the area between the notch 81a, 81b and the surface in which the bevel 10 has now been formed has been pressed into the notch 81a, 81b. Thus, the shape of each notch 81a, 81b has changed.

[0413] Fig.19D A cross section of a building panel 1 after a finishing process is shown, wherein a mechanical locking device 100 has been created in the edge of the building panel 1. After the beveling process, the remaining notches 81a, 81b no longer exist after the finishing process creating the mechanical locking device 100. However, in one embodiment, at least some of the space previously occupied by the notches is now open space for the locking system. Furthermore, a bevel 10 of the desired length has been created by the finishing process.

[0414] 20-25 show different steps of a possible arrangement for processing a panel blank 2 and producing a plurality of building panels 1 therefrom. Fig. 20A and Fig. 20B A panel blank 2 is shown. The panel blank 2 comprises the same layers as the building panel 1 produced therefrom, i.e. a single-layer or multi-layer substrate 3, a sublayer 5 plastically deformable under pressure, and a surface layer 7, which preferably comprises a decorative layer and a wear layer. Obviously, all previously described materials, layers and manufacturing methods for forming the building panel 1 are also applicable to forming the panel blank 2, since the final product of the panel blank 2 is a building panel 1 as described above with reference to e.g. Figures 1-9. Fig. 20A and 20B The panel blank 2 is shown after all layers have been bonded together by pressure and preferably also by heating.

[0415] Fig.21A and Fig.21BA groove forming process 92 for forming one or more grooves 11 in a panel stock 2 is shown. The groove forming process 92 comprises a pressing device 93 having one or more pressing elements 94a-94d, in the example shown there are four pressing elements 94a-94b. The pressing elements 94a-94d are arranged at predetermined intervals along a rod element 95. The distance between each pressing element 94a-94d is determined by the proportions of the building panel 1 to be produced later, for example by the width of the building panel 1.

[0416] The pressing elements 94a-94d preferably have an annular / circular shape so that the pressing elements 94a-94d can roll on the panel stock 2. The outer shape of each pressing element 94a-94d has a curved outer surface 96, such as a convex surface or a curved surface with a cross section of different shapes, wherein the curved outer surface 96 produces a groove 11 in the panel stock 2. The pressing elements 94a, 94d arranged at the outer edge 2' of the panel stock 2 are configured to produce at least one ramp surface 97a, 97b in the panel stock 2 by means of their curved outer surface 96. The ramp surfaces 97a, 97b in the panel stock 2 will later become the bevel 10 of the building panel 1. The pressing elements 94b, 94c arranged away from the outer edge 2' of the panel stock 2 are configured to produce two ramp surfaces 97a, 97b in the panel stock 2 by means of their curved outer surface 96. The two sloped surfaces 97a, 97b in the panel stock 2 will later each become the bevel 10 of the building panel 1. Between the two sloped surfaces 97a, 97b of the panel stock 2 there may be an intermediate surface 97c in which the cutting device will later cut the panel stock 2 into the building panel 1, thereby separating the two sloped surfaces 97a, 97b.

[0417] The groove forming process 92 may also include a heating device (not shown). The heating device may be a separate device or combined in the pressing device 93. Heating the area of ​​the panel original board to be produced therein with the groove 11 may make the groove forming process 92 easier. Depending on the process setting of the manufacturing method, the heating device may not be necessary. If the panel original board 2 is directly transferred from the process in which the panel original board 2 is formed by heat and pressure, the panel original board may actually still be hot enough to make the groove 11 by the pressing device 93. Therefore, there are multiple possible settings for the manufacturing process. The at least one groove 11 may be produced while the panel original board is formed by heat and pressure (described below), or the at least one groove 11 may be produced in the process after the process of forming the panel original board 2, but the heat used in the process of forming the panel original board 2 is sufficient for the subsequent groove forming process, or the at least one groove 11 may be formed in the process after the process of forming the panel original board 2, wherein the groove forming process includes heating the panel original board 2 at least in the area to be produced therein with the groove, or even the groove forming process is performed without heating, and only pressure is used to form the at least one groove 11.

[0418] If heat is used in any way to form at least one groove 11 in the panel stock 2, it is preferred to have a cooling process (not shown), similar to that described above with reference to Fig.15A and 15B The process described above for forming bevels in building panels. Therefore, this cooling process is also applicable to the method of forming grooves in panel stock, just as it is for forming bevels in building panels.

[0419] The result of the groove forming process 92 can be found in Fig.22A and 22B Seen in.

[0420] An alternative to the groove forming process described above (not shown) is to press at least one groove with a sloped surface into the panel blank while forming the panel blank and bonding the layers, i.e. base layer, sublayer and surface layer together. The at least one groove may be produced by the same pressing device while forming the panel blank. The pressing device may then preferably be provided with features, such as protrusions, for producing such a groove with a sloped surface, which is configured to become the inclined surface of the later formed building panel.

[0421] After the groove forming process, the panel raw board 2 enters a cutting process 98, in which a plurality of building panels 1 are produced from the panel raw board 2, such as Fig.23A and 23BAs shown. The cutting process 98 includes one or more cutting devices 99a-99d, four in the example shown. In the example shown, the cutting devices 99a-99d are saws, but in other examples may be other types of cutting devices, such as punching devices or lasers. The cutting devices 99a-99d are arranged at predetermined intervals and are configured to cut the panel stock 2 so that the building panels 1 obtain their desired proportions. The cutting devices 99a-99d are configured to cut in the middle surface 97c of each groove 11 between the sloped surfaces 97a, 97b generated by the groove forming process 92.

[0422] In addition, the cutting process 98 may also include any of the finishing processes described above, i.e., Fig.16A and 16B , Fig.17A and 17B as well as Fig.18A and 18B The final edge shaping process of the building panel 1 is described.

[0423] Possible results of the cutting process 98 can be found in Fig.24A and 24B , where a plurality of building panels 1 are arranged adjacent to each other / one after the other and each building panel 1 is provided with a mechanical locking device 100 .

[0424] Fig.25 According to the method described above and with reference to Figures 20A-24B Overview of the steps of producing a building panel 1 having a bevel 10 from a panel stock 2.

[0425] Below is an example from a test groove formation process 92. Fig.26 The photographs show the results of mixing 40 g of plasticizer with 300 g of PVC blend according to Table 1. In Table 2, the groove depths obtained by testing different amounts of plasticizer with PVC blends are shown.

[0426] Figures 27A-27C The photographs show the results of a test bevel forming process, wherein the building panels 1 each have a foamed sublayer 5. In the example shown, the sublayer 5 is made of foamed PET. The tests have shown that bevels pressed at any temperature in the range of 100°C to 140°C obtain the same Figures 27A-27C The same beneficial effects are shown.

[0427] Fig.27A For example, through Figures 14A-14C The method shown produces a photograph of two building panels 1 after the intended edge but before cutting the building panels. Fig.27B yes Fig.27A Photo of two building panels after they have been cut at the edges. Fig.27Care placed next to each other Fig.27B Photograph of two building panels in order to illustrate possible assembly positions, in this case without mechanical locking devices.

[0428] Example

[0429] Below are test results showing the correlation between groove formation and sublayer content using predetermined temperature, pressure, and time.

[0430] A certain number of building panels with the same core, the same surface layer but with sub-layers having different amounts of plasticizer were produced in a pressing device at a pressure of 20 bar, a temperature of 80° C. within 35 seconds. The pressing device was equipped with a top press plate which had grooves 1.2 mm deep. The grooves produced by the press plate in the building panels were then measured. The results are shown in Table 2 below.

[0431] Two reference tests were performed, one without any sublayer, just the substrate and the surface layer, which included the decorative layer and the wear layer, and the other with a sublayer between the substrate and the surface layer, where the sublayer had no plasticizer in the blend.

[0432] The substrate used in the test was an SPC core, which is commonly used in the field. The surface layer included a decorative print layer and a wear layer, wherein the print layer was arranged on top of the plastically deformable sublayer and the wear layer was arranged on top of the print layer.

[0433] For the tests, PVC blends were mixed with different amounts of plasticizers. The main PVC blend formulations are defined in Table 1. The majority of the blend consists of PVC (68.97%) and the inorganic filler chalk (22.07%).

[0434] Table 1: PVC blending formula

[0435]

[0436] 300 g of the PVC blend according to Table 1 was mixed with different amounts of plasticizer according to Table 2. The plasticizer (Plast.) used for the test was Eastman 168. The grooves of each test were measured, and the depth value X of the grooves was measured from the upper surface of the wear layer between two grooves to the bottom of the groove.

[0437] Table 2: Sublayers with different amounts of plasticizer

[0438] Sublayer Plasticizer weight % Depth of groove X(mm) SPC core + no sublayer - 0.027 PVC blend + no plasticizer 0 0.027 PVC blend + 8g plasticizer 2.6 0.041 PVC blend + 20g plasticizer 6.3 0.041 PVC blend + 27g plasticizer 8.3 0.069 PVC blend + 40g plasticizer (in Fig.26 (shown in 11.8 0.124 PVC blend + 60g plasticizer 16.7 0.110 PVC blend + 80g plasticizer 21.1 0.110 PVC blend + 100g plasticizer 25.0 0.124

[0439] It was concluded from the test results that the plasticizer in the material blend of the sub-layer provided the sub-layer with the desired plastic deformation characteristics. Furthermore, the depth of the grooves in the building panels increased with increasing amount of plasticizer in the blend.

[0440] Finally, although the concept of the present invention has been described above with reference to specific embodiments, the present invention is not intended to be limited to the specific forms set forth herein. On the contrary, the present invention is limited only by the appended claims. Other embodiments than the above-described specific embodiments are equally possible within the scope of the appended claims. All embodiments may be used alone or in combination. Angles, sizes, rounded portions, spacing between surfaces, etc. are merely examples and may be adjusted within the basic principles of the present invention.

[0441] Project Section

[0442] Item 1. A method for manufacturing a building panel (1), such as a floor panel or a wall panel, comprising:

[0443] combining a substrate material and a sublayer material to form a substrate (3) and a sublayer (5) of a building panel (1), wherein the sublayer material comprises a polymer-based material;

[0444] applying a surface layer (7) on the sublayer (5);

[0445] applying pressure to form the building panel (1); and

[0446] A bevel (10) is formed along at least one edge (15, 16, 17, 18) of a building panel (1) by applying pressure by means of a pressing device and by plastic deformation of a sublayer (5).

[0447] Item 2. The method of Item 1, wherein applying pressure to form the building panel (1) further comprises applying heat.

[0448] Item 3. The method according to item 1 or 2, wherein forming the bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1) by means of the pressing device further comprises applying heat.

[0449] Item 4. The method according to any one of the preceding items further comprises cooling after the bevel (10) is formed by means of the pressing device.

[0450] Item 5. The method according to any one of the preceding items, wherein the polymer-based material of the sub-layer material forming the sub-layer (5) is a thermoplastic material.

[0451] Item 6. The method according to any one of the preceding items, wherein the sub-layer material further comprises at least one filler, and wherein the filler is preferably at least one mineral-based filler.

[0452] Item 7. The method according to any one of the preceding items, further comprising:

[0453] Before forming a bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1) by means of a pressing device, a notch (81a, 81b) is produced in an edge portion of the at least one edge (15, 16, 17, 18) of the building panel (1).

[0454] Item 8. The method according to Item 7 further includes:

[0455] Before forming a bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1) by means of a pressing device, at least the area of ​​the building panel (1) between the notch (81a, 81b) and the surface (4, 8) is heated.

[0456] Item 9. The method according to any one of the preceding items, further comprising:

[0457] After forming a bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1) by means of a pressing device, at least one edge (15, 16, 17, 18) of the building panel (1) is finished.

[0458] Item 10. The method according to any one of the preceding items, further comprising:

[0459] A mechanical locking device (100, 100') is produced along at least one edge (15, 16, 17, 18) of a building panel (1), wherein the mechanical locking device (100, 100') is configured for locking similar or substantially identical building panels (1, 1', 1") horizontally and / or vertically in an assembled position.

[0460] Item 11. A method for manufacturing a building panel (1), such as a floor panel or a wall panel, comprising:

[0461] combining a substrate material and a sublayer material to form a substrate (3) and a sublayer (5) of a panel stock (2), wherein the sublayer material comprises at least a polymer-based material;

[0462] applying a surface layer (7) on the sublayer (5);

[0463] applying pressure to form a panel blank (2);

[0464] forming a groove (11) in the panel stock (2) by applying pressure by means of a pressing device and by plastic deformation of the sub-layer (5); and

[0465] forming a building panel (1) from the panel stock (2),

[0466] The groove (11) is configured to form a bevel (10) along at least one edge (15, 16, 17, 18) of the building panel (1).

[0467] Item 12. The method according to Item 11, wherein the polymer-based material of the sub-layer material forming the sub-layer (5) is a thermoplastic material.

[0468] Item 13. The method according to Item 11 or 12, wherein the sub-layer material further comprises at least one filler, and wherein the filler is preferably at least one mineral-based filler.

[0469] Item 14. The method according to any one of Items 11 to 13, wherein the groove (11) is formed in the panel original board (2) after the panel original board (2) is formed.

[0470] Item 15. The method of any one of items 11 to 14, wherein forming a building panel (1) from the panel stock (2) comprises cutting the panel stock (2) at the groove (11).

[0471] Item 16. The method according to any one of Items 11 to 15, wherein applying pressure to form the panel original board (2) and / or to form the groove (11) also includes applying heat.

[0472] Item 17. The method according to any one of Items 11 to 16, further comprising cooling after the groove (11) is formed in the panel original board (2).

[0473] Item 18. The method according to any one of Items 11 to 17, further comprising:

[0474] After forming a building panel (1) from the panel blank (2), the at least one edge (15, 16, 17, 18) of the building panel (1) is finished.

[0475] Item 19. The method according to any one of Items 11 to 18, further comprising:

[0476] After forming a building panel (1) from said panel blank (2), a mechanical locking device (100, 100') is produced along at least one edge (15, 16, 17, 18) of the building panel (1), wherein the mechanical locking device (100, 100') is configured for locking similar or substantially identical building panels (1, 1', 1") horizontally and / or vertically in an assembled position.

[0477] Item 20. A building panel manufactured by the method according to any one of the preceding items.

[0478] Item 21. A method for forming a bevel along at least one edge of a building panel, the method comprising:

[0479] Providing a building panel (1) comprising a substrate (3), a sublayer (5) and a surface layer (7), wherein the sublayer (5) is arranged between the substrate (3) and the surface layer (7), and wherein the sublayer (5) comprises a polymer-based material; and

[0480] A bevel (10) is formed along at least one edge (15, 16, 17, 18) of a building panel (1) by plastic deformation of a sublayer (5).

[0481] Item 22. The method according to Item 21, wherein forming the bevel (10) along at least one edge (15, 16, 17, 18) of the building panel (1) by plastic deformation of the sublayer (5) comprises applying pressure by a pressing device.

[0482] Item 23. The method according to item 21 or 22, wherein forming the building panel (1) comprises combining the substrate (3), the sublayer (5) and the surface layer (7) by applying pressure to form the building panel (1).

[0483] Item 24. The method according to item 22 or 23, wherein after applying pressure to form the building panel (1), pressure is applied by a pressing device to form the chamfer (10).

[0484] Item 25. A method for forming a bevel along at least one edge of a building panel, the method comprising:

[0485] Providing a panel stock (2) comprising a substrate (3), a sublayer (5) and a surface layer (7), wherein the sublayer (5) is arranged between the substrate (3) and the surface layer (7), and wherein the sublayer (5) comprises a polymer-based material; and

[0486] Forming a groove (11) in the panel stock (2) by plastic deformation of the sub-layer (5);

[0487] forming at least one building panel (1) from the panel stock (2); and

[0488] The groove (11) is configured to form a bevel (10) along at least one edge (15, 16, 17, 18) of the at least one building panel (1).

[0489] Item 26. The method of Item 25, wherein forming the groove (11) along at least one edge (15, 16, 17, 18) of the building panel (1) by plastic deformation of the sublayer (5) comprises applying pressure by a pressing device.

[0490] Item 27. The method according to Item 25 or 26, wherein forming the panel original board (2) includes combining the substrate (3), the sublayer (5) and the surface (7) by applying pressure to form the panel original board (2).

[0491] Item 28. The method according to item 26 or 27, wherein after applying pressure to form the building panel (1), pressure is applied by a pressing device to form the groove (11).

[0492] Item 29. The method of any one of items 25 to 28, wherein forming a building panel (1) from the panel stock (2) comprises cutting the panel stock (2) at the groove (11).

Claims

1. A method for forming a bevel along at least one edge of a building panel, the method comprising: Providing a building panel (1) comprising a substrate (3), a sublayer (5) and a surface layer (7), wherein the sublayer (5) is arranged between the substrate (3) and the surface layer (7), wherein the sublayer (5) comprises a polymer-based material; and A bevel (10) is formed along at least one edge (15, 16, 17, 18) of the building panel (1) by applying pressure by means of a pressing device and by plastic deformation of the sublayer (5).

2. The method according to claim 1, wherein: Forming a bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1) further comprises applying heat.

3. The method according to claim 1 or 2, further comprising cooling the bevel (10) by means of a cooling device (87a, 87b) after forming the bevel (10).

4. The method according to any one of the preceding claims, further comprising: Before forming the bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1), a notch (81a, 81b) is created in an edge portion of the at least one edge (15, 16, 17, 18) of the building panel (1).

5. The method according to claim 4, further comprising: Before forming the bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1), at least the area between the notch (81a, 81b) and the surface (4, 8) of the building panel (1) is heated.

6. The method according to any one of the preceding claims, further comprising: After forming the bevel (10) along the at least one edge (15, 16, 17, 18) of the building panel (1), finishing the at least one edge (15, 16, 17, 18) of the building panel (1).

7. A method according to any one of the preceding claims, wherein: The polymer-based material of the sub-layer material forming the sub-layer (5) is a thermoplastic material, wherein the amount of the thermoplastic material in the sub-layer material is preferably at least 10 wt%, at least 15 wt% or at least 20 wt%.

8. A method for producing a building panel (1), such as a floor panel or a wall panel, the method comprising: combining a substrate material and a sublayer material to form a substrate (3) and a sublayer (5) of a building panel (1), wherein the sublayer material comprises a polymer-based material; applying a surface layer (7) on the sublayer (5); applying pressure to form the building panel (1); as well as A bevel (10) is formed along at least one edge (15, 16, 17, 18) of the building panel (1) by means of a method according to any one of claims 1 to 6.

9. The method according to claim 8, wherein: The polymer-based material of the sub-layer material forming the sub-layer (5) is a thermoplastic material, wherein the amount of thermoplastic material in the sub-layer material is preferably at least 10 wt%, at least 15 wt% or at least 20 wt%.

10. The method according to claim 8 or 9, wherein: The sub-layer material further comprises at least one filler, wherein the filler is preferably at least one mineral-based filler.

11. The method according to any one of claims 8 to 10, further comprising: A mechanical locking device (100, 100') is created along at least one edge (15, 16, 17, 18) of the building panel (1), wherein the mechanical locking device (100, 100') is configured for locking similar or substantially identical building panels (1, 1', 1") horizontally and / or vertically in an assembled position.

12. The method according to any one of claims 8 to 11, wherein: Applying pressure to form the bevel (10) is performed after applying pressure to form the building panel (1).

13. A method for forming a bevel along at least one edge of a building panel, the method comprising: Providing a panel stock (2) comprising a substrate (3), a sublayer (5) and a surface layer (7), wherein the sublayer (5) is arranged between the substrate (3) and the surface layer (7), wherein the sublayer (5) comprises a polymer-based material; forming a groove (11) in the panel stock (2) by applying pressure by means of a pressing device and by plastic deformation of the sub-layer (5); as well as at least one building panel (1) is formed from the panel stock (2), and Wherein the groove (11) is configured to form a bevel (10) along an edge (15, 16, 17, 18) of the at least one building panel (1).

14. The method according to claim 13, wherein: Forming a building panel (1) from the panel blank (2) comprises cutting the panel blank (2) in the groove (11).

15. The method according to claim 13 or 14, further comprising cooling the groove (11) by means of a cooling device after forming the groove (11) in the panel original plate (2).

16. A method for manufacturing a building panel (1), such as a floor panel or a wall panel, the method comprising: combining a substrate material and a sublayer material to form a substrate (3) and a sublayer (5) of a panel stock (2), wherein the sublayer material comprises a polymer-based material; applying a surface layer (7) on the sublayer (5); Applying pressure to form the panel blank (2); forming a groove (11) in the panel stock (2) by applying pressure by means of a pressing device and by plastic deformation of the sub-layer (5); as well as forming a building panel (1) from the panel stock (2), The groove (11) is configured to form a chamfer (10) along an edge (15, 16, 17, 18) of the building panel (1).

17. The method according to claim 16, wherein: Applying pressure by the pressing device to form the groove (11) is performed after applying pressure to form the panel blank (2).

18. The method according to claim 16 or 17, wherein: The polymer-based material of the sub-layer material forming said sub-layer (5) is a thermoplastic material.

19. The method according to any one of claims 16 to 18, wherein: Forming a building panel (1) from the panel blank (2) comprises cutting the panel blank (2) in the groove (11).

20. The method according to any one of claims 16 to 19, wherein: Applying pressure to form the panel blank (2) and / or applying pressure to form the groove (11) further comprises applying heat.

21. The method according to any one of claims 16 to 20, further comprising: After forming a building panel (1) from the panel blank (2), the at least one edge (15, 16, 17, 18) of the building panel (1) is finished.

22. The method according to any one of claims 16 to 21, further comprising: After forming a building panel (1) from the panel blank (2), a mechanical locking device (100, 100') is produced along at least one edge (15, 16, 17, 18) of the building panel (1), wherein the mechanical locking device (100, 100') is configured for locking similar or substantially identical building panels (1, 1', 1") horizontally and / or vertically in an assembled position.

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