Method for producing ramp on building panel and such building panel

Abstract

A method for producing a bevel at least partially along at least one edge of a building panel (1), such as a floor panel or a wall panel, where the building panel (1) comprises a polymer-based material. The method comprises creating a notch in an edge portion of at least one edge of the building panel (1), wherein the notch is located at a distance from a surface (8) of the building panel (1) in a direction substantially perpendicular to the surface (8) of the building panel (1). The method further comprises heating at least a region between the notch and the surface (8) of the building panel (1) in which the bevel is to be formed, and applying pressure to the surface (8) to form the bevel of the building panel (1).

Description

Technical Field

[0001] The present invention relates to the field of building panels, in particular to the field of floor panels or wall panels. In particular, the present invention relates to a method for producing a bevel on such a building panel. 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.

[0004] However, such panels generally have limitations and disadvantages in their manufacturing process, since the cores of these panels are generally made of highly filled thermoplastic materials, thermosetting materials, hardwood substrates or inorganic materials such as mineral-based materials. These types of cores are generally very hard, and therefore it is difficult to form the desired embossing and / or bevels thereon. For example, if an SPC panel or another thermoplastic board is laminated, embossed and / or provided with a bevel, it is necessary to use a large amount of surface material to achieve the appropriate and desired shape of the embossing and / or bevel.

[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 producing a bevel at least partially along at least one edge of a building panel, such as a floor panel or a wall panel, wherein the building panel comprises a polymer-based material, the method comprising:

[0008] creating a notch in an edge portion of the at least one edge of the building panels, wherein the notch is located at a distance from the surface of the building panels in a direction substantially perpendicular to the surface of the building panels in which the chamfer is to be formed;

[0009] heating at least a region between the notch and the surface of the building panel in which the bevel is to be formed;

[0010] Pressure is applied to the surface to form a bevel in the building panel.

[0011] The bevel may be formed at the edge portion.The bevel may extend at least partially along the at least one edge of the building panel.

[0012] 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.

[0013] 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 the substrate. In one embodiment, the shape and size of the bevel may depend on the size and position of the mechanical locking device, as described in more detail below.

[0014] 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.

[0015] The bevel may further be curved with a radius of 1 mm to 10 mm.

[0016] 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.

[0017] By creating notches, a bevel may be formed in a building panel or a substrate of a building panel, which bevel may otherwise be difficult to form.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] In fact, whatever the final processing step along the edge of the building panel (e.g. calibration / finishing / trimming), 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.

[0023] 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.

[0024] In another embodiment, the height of the opening of the notch before the bevel is formed exceeds the height of the bevel.

[0025] 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.

[0026] 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.

[0027] Since the bevel contributes to the aesthetic appearance of the building panels, the bevel is usually formed in the edge located in the top surface of the building panels, so as mentioned above, the surface of the building panels is usually the front surface of the building panels. However, it can alternatively be the back surface of the building panels.

[0028] The pressure applied when forming the bevel may be 1-20 bar, depending on the temperature of the material when forming the bevel.

[0029] 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, etc.

[0030] In one embodiment, the polymer-based material of the building panel is a thermoplastic material, which may preferably 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), polyacrylatemethacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof.

[0031] The building panels may comprise polymer-based materials such as thermoplastic materials in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

[0032] In one embodiment, the building panel comprises a substrate and a surface layer. The substrate is formed of a substrate material, which may comprise a polymer-based material. The surface layer may comprise a decorative layer and / or a wear layer. The substrate may be a single-layer substrate or a multi-layer substrate.

[0033] The surface layer may be a single-layer surface layer or a multi-layer surface layer.

[0034] In one embodiment, the decorative layer is a printed polymer base. In another embodiment, 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 or nonwoven).

[0035] In one embodiment, the wear resistant layer may be a wear resistant foil, a wear resistant layer with wear resistant particles and / or a paint layer and / or a coating.

[0036] The polymer-based material of the substrate may be a thermoplastic material, which is preferably 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.

[0037] 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%.

[0038] The substrate 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%.

[0039] The substrate material may further include one or more fillers, which are at least one or more of organic fillers, inorganic fillers, and combinations thereof.

[0040] 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 material may comprise 1-70 wt % of the organic filler, or 30-70 wt % of the organic filler.

[0041] 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.

[0042] In one embodiment, the substrate comprises a mineral-based filler and comprises 1-80 wt% of the mineral-based filler.

[0043] The inorganic filler of the substrate material may be a mineral-based filler, such as calcium carbonate (CaCO 3 ).

[0044] The substrate material may also 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 substrate material forming the substrate may contain a plasticizer in an amount of 1-30 wt% or 2-15 wt%.The plasticizer provides the substrate with desirable formable properties.

[0045] Another method of producing the desired formable properties of the substrate is that the substrate comprises at least two different types of polymers. For example, the substrate may comprise a material blend comprising a PVC / PVAc copolymer, wherein the PVAc content in the substrate material blend may be 1-20 wt %, and the PVC content in the material blend may be 80-99 wt %.

[0046] 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.

[0047] 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, namely 10-40wt%, 15-35wt% or 20-30wt% thermoplastic material, 50-90wt%, 60-80wt% or 65-75wt% filler, typically an inorganic filler, and 0-20wt%, 1-15wt% or 2-10wt% additives, but with 1-20wt%, 2-15wt% or 3-10wt% plasticizer added.

[0048] In one embodiment, the substrate 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.

[0049] In one embodiment, the notch is at least partially located in the substrate. In another embodiment, the notch is completely located in the substrate. When the substrate is plastically deformable under pressure and optionally also heated, it is particularly advantageous to at least partially or completely create the notch in the substrate. Discussion about plastic deformation is provided later in this disclosure.

[0050] In an alternative embodiment, the breach is at least partially located in the superficial layer. In another alternative embodiment, the breach is completely located in the superficial layer. When substrate can not fully plastically deform under pressure and optionally also have heating, it is particularly advantageous to produce breach at least partially or entirely in the superficial layer.

[0051] In one embodiment, the indentations are located in both the substrate and the surface layer around the interface between the substrate and the surface layer.

[0052] In one embodiment, the aperture is located partially in the substrate and partially in the surface layer.

[0053] The notch may be formed in the surface layer and extend at least 10%, at least 20% or at least 30% into the surface layer. In one embodiment, the notch may be formed in the surface layer and extend at least 90% into the surface layer.

[0054] Preferably the notch extends along the entire length of at least one edge of the building panel along which the bevel is to be formed.

[0055] In one embodiment the notch extends into an edge portion of at least one edge in a direction substantially parallel to the surface of the building panel.

[0056] In another embodiment the notches extend in a direction substantially perpendicular to the direction in which the bevel of the building panel forms the surface.

[0057] The notch is preferably a temporary feature of the edge of the building panel which no longer assumes its original shape during the final forming process, ie the finishing process.

[0058] The method may further include:

[0059] The bevel is cooled and the area between the notch and the surface of the building panel where the bevel is formed is at least partially cooled. By adding a cooling step, the elasticity and / or recovery effect of the bevel and / or the material in the building panel can be more easily controlled and thus the final appearance of the bevel of the building panel can be controlled. Another advantage of having a cooling step is that it can 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 can be stopped.

[0060] In one embodiment cooling is performed during application of pressure to the surface to form the bevel of the building panel.

[0061] 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.

[0062] 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.

[0063] In a second aspect, there is provided a method for manufacturing a building panel, such as a floor panel or a wall panel, wherein the building panel comprises a polymer based material, the method comprising:

[0064] applying a surface layer to a substrate, wherein the surface layer includes a decorative layer;

[0065] applying pressure to form building panels; and

[0066] A bevel is formed along at least one edge of a building panel using a method according to any of the embodiments above.

[0067] In one embodiment applying pressure to form the building panels further comprises applying heat.

[0068] The method may further include:

[0069] 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 and the building panel. Such a finishing step may be achieved, for example, by cutting, milling and / or grinding.

[0070] 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.

[0071] In an alternative embodiment, the step of finishing the edge may comprise creating an angled / sloped edge surface, wherein the edge of the front surface preferably protrudes from a plane arranged in the edge of the rear surface extending substantially perpendicularly to the front surface. That is, the inclined surface preferably slopes inwardly towards the rest of the building panels from the front surface to the rear surface of the building panels.

[0072] 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.

[0073] In a further embodiment the step of finishing at least one edge of the building panels comprises producing mechanical locking means 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.

[0074] Preferably, each notch may be temporary, which no longer exists after finishing the at least one edge of the building panel.

[0075] The method may further include:

[0076] The adhesive is applied to the substrate before the surface layer is applied to the substrate so that the adhesive is arranged between the substrate and the surface layer, or the adhesive is applied to the surface layer before the surface layer is applied to the substrate so that the adhesive is arranged between the substrate and the surface layer.

[0077] In one embodiment, the adhesive may be glue.

[0078] The amount of adhesive applied between the substrate and the surface layer can be 50g / m 2 Up to 200g / m 2 within the range.

[0079] In a third aspect, there is provided a building panel manufactured by a method according to any of the above embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0080] 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.

[0081] Figure 1A is a schematic perspective view of a building panel according to an embodiment of the present inventive concepts;

[0082] Figure 1B is a schematic top view of a building panel according to an embodiment of the present inventive concepts;

[0083] Figure 2A schematically illustrates an assembly of a plurality of building panels;

[0084] Figure 2B Schematically shows Figure 2A Finished components;

[0085] Figure 3A 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;

[0086] Figure 3B Schematically shows the assembled position Figure 3A A cross section of two opposite edge portions of;

[0087] Figure 3C Schematic diagram showing the assembly process Figure 3A A cross section of two opposite edge portions;

[0088] Figure 4Aschematically 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;

[0089] Figure 4B Schematically shows the assembled position Figure 4A A cross section of two opposite edge portions of;

[0090] Figure 4C Schematic diagram showing the assembly process Figure 4A A cross section of two opposite edge portions;

[0091] 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 a further embodiment of the inventive concept;

[0092] Figure 5B Schematically shows the assembled position Figure 5A A cross section of two opposite edge portions of;

[0093] Figure 5C Schematic diagram showing the assembly process Figure 5A A cross section of two opposite edge portions;

[0094] Figure 6 schematically shows a side view of a cross section of a building panel before the desired edge of the finished building panel is produced;

[0095] Fig. 7A Schematically illustrates step one of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0096] Figure 7B yes Fig. 7A Detailed view of

[0097] Figure 7C Schematically shows the Fig. 7A a side view of a cross section of the building panel after step one of;

[0098] Fig. 8A Schematically illustrates step two of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0099] Figure 8B yes Fig. 8A Detailed view of

[0100] Fig.9ASchematically illustrates step three of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0101] Fig. 9B yes Fig.9A Detailed view of

[0102] Fig. 9C Schematically shows the Fig.9A a side view of a cross section of the building panel after step three in;

[0103] Fig. 10A schematically illustrates step four of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0104] Fig. 10B yes Fig. 10A Detailed view of

[0105] Fig.11A 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;

[0106] Fig. 11B Schematically shows the Fig.11A a side view of a cross section of a building panel after the steps in;

[0107] Fig. 12A schematically illustrate the steps of another finishing method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0108] Fig. 12B Schematically shows the Fig. 12A a side view of a cross section of a building panel after the steps in;

[0109] Fig.13A 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;

[0110] Fig. 13B yes Fig.13A Detailed view of

[0111] Fig. 13C Schematically shows the Fig.13A a side view of a cross section of a building panel after the steps in;

[0112] Fig.14A schematically shows a side view of a cross section of a building panel before producing an alternative intended edge of the finished building panel;

[0113] Fig. 14BSchematically 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.14A A side view of a cross section in FIG.

[0114] Fig. 14C Schematically shows the Fig. 14B Method for producing a beveled surface of a building panel according to an embodiment of the inventive concept after the steps of Fig.14A A side view of a cross section in FIG.

[0115] Fig.14D Schematically shows the Fig. 14C 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.14A A side view of a cross section in FIG.

[0116] Fig.15A schematically shows a side view of a cross section of a building panel before producing another alternative intended edge of the finished building panel;

[0117] Fig. 15B 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.15A A side view of a cross section in FIG.

[0118] Fig. 15C Schematically shows the Fig. 15B Method for producing a beveled surface of a building panel according to an embodiment of the inventive concept after the steps of Fig.15A A side view of a cross section in FIG.

[0119] Fig.15D Schematically shows the Fig. 15C The finishing method for producing a substantially straight surface of a building panel according to an embodiment of the inventive concept is performed after the steps in Fig.15A A side view of a cross section in FIG.

[0120] Fig.15E Schematically shows the Fig. 15C The finishing method for producing an inclined surface of a building panel according to an embodiment of the inventive concept after the steps in Fig.15A Side view of a cross section in FIG. DETAILED DESCRIPTION

[0121] Specific embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein; on the contrary, these embodiments are provided to make this disclosure thorough and complete and to fully convey the scope of the present 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 present invention. In the accompanying drawings, the same reference numerals represent the same elements.

[0122] 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 a direction substantially parallel to the extension of the decorative surface and a direction substantially 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 substantially parallel to the extension of the decorative surface, and the vertical direction is the same as the direction substantially perpendicular to the extension of the decorative surface.

[0123] In the present disclosure, plastically deformable substrates 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 with grooves having 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 depression of 0.04 mm. 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.

[0124] 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.

[0125] The purpose of making the substrate plastically deformable is to allow easier and / or deeper forming of bevels and / or embossed building panels during the manufacturing process.

[0126] The method of manufacturing different layers into a building panel (e.g. a floor panel or a wall panel) that can be used within the inventive concept of the present application can be any suitable method. For example, such a method can include: applying a surface layer to a substrate, wherein the surface layer includes a decorative layer; and applying pressure to form the building panel. Applying pressure to form the building panel can also include applying heat.

[0127] The method may further include applying an adhesive to the substrate before applying the surface layer to the substrate, so that the adhesive is arranged between the substrate and the surface layer, or applying an adhesive to the surface layer before applying the surface layer to the substrate, so that the adhesive is arranged between the substrate and the surface layer. In this application, the adhesive may be glue. The amount of adhesive applied between the substrate and the surface layer may be 50 g / m 2 Up to 200g / m 2 within the range.

[0128] Referring to the drawings, there is shown a building panel 1, for example see Figure 1A and 1B The building panels 1 shown have a rectangular / cuboid shape, but in other embodiments may have any other suitable shape, such as square, triangular or hexagonal. Each building panel 1 may have at least a substrate 3 and a surface layer 7 .

[0129] The substrate 3 is arranged at the back side of the building panel 1. The lower side of the substrate 3 forms the rear surface 4 of the building panel 1. The upper side of the substrate 3 is attached to a surface layer 7.

[0130] The building panel 1 may be a single layer substrate or a multi-layer substrate.A multi-layer substrate may comprise two or more layers, such as a core layer, a backing layer, a balancing layer, a reinforcement layer, a mineral based layer or an insulation layer.

[0131] The substrate 3 may preferably be configured such that it is plastically deformable when at least pressure, and preferably also heat, is applied to the substrate 3 or the surface layer 7. This is advantageous when forming the bevel 10 at the edges 15, 16, 17, 18 of the building panel 1, for example by means of pressing. The method of forming the bevel 10 will be described in more detail below.

[0132] Substrate 3 comprises substrate material, and this substrate material comprises polymer-based material, and this polymer-based material is preferably thermoplastic material.Thermoplastic material can be selected from the group comprising following material: 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.Substrate material can comprise polymer-based material such as thermoplastic material in the amount of at least 10wt%, at least 15wt% or at least 20wt%.

[0133] The substrate material may preferably contain less than 10 wt % of wood-based materials, or less than 5 wt % of wood-based materials.

[0134] 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 coconut or bamboo fibers. 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.

[0135] 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 contain a plasticizer in an amount of 1-30 wt% or 2-15 wt%.Having a plasticizer in the substrate material is a way of making the substrate 3 plastically deformable under the influence of pressure and preferably also heat.

[0136] Another way to make the substrate 3 plastically deform under pressure and preferably also heat is to include at least two different types of polymers. For example, the substrate material may include a material blend containing a PVC / PVAc copolymer, wherein the PVAc content in the material blend of the substrate is 1-20wt%.

[0137] In addition, the substrate material may contain plastisol. Plastisol gives the substrate 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.

[0138] In one embodiment, the sub-layer material consists of plastisol.

[0139] 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.

[0140] 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.

[0141] The substrate 3 preferably has a thickness of 1-10 mm, a thickness of 2-8 mm, or a thickness of 3-7 mm.

[0142] A surface layer 7 is arranged on the substrate 3 above the substrate 3. The upper side of the surface layer 5 forms the front surface 8 of the building panel 1 .

[0143] 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 7 comprises at least a decorative layer and a wear layer, wherein the decorative layer is arranged between the substrate 3 and the wear layer, and the wear layer is the uppermost layer of the building panel 1 .

[0144] 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.

[0145] The wear resistant layer may be a wear resistant foil, a wear resistant layer comprising wear resistant particles and / or a lacquered layer and / or a coating. The wear resistant layer is preferably a transparent layer, ie a layer which does not affect the appearance of the decorative layer arranged below.

[0146] Figure 1B 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.

[0147] Figure 1A and 1B The building panel 1 in FIG. 1 is shown to have a rectangular / cuboid shape, but may have a different shape in other embodiments. However, the 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.

[0148] 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 in a direction substantially perpendicular thereto.

[0149] 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 the bevel 10 may also be provided along the short sides, or along both the short sides and the long sides.

[0150] The upper part 20 is located at the front surface 8 of the building panel 1 and may comprise the surface layer 7 and at least part of the substrate 3. If desired, the bevel 10 may also be arranged along the third and fourth edge. The bevel 10 may extend along the entire extension length of the edge 15, 16 on which the bevel 10 is arranged. A schematic diagram of the bevel 10 may be seen in Figures 3A-5C Seen in.

[0151] The bevel 10 may extend into the surface layer 7 or into the surface layer 7 and into the substrate 3 in a direction substantially perpendicular to the front surface 8 .

[0152] Furthermore, the building panel 1 comprises 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 substantially perpendicular and / or substantially parallel to the rear or front surface 4, 8.

[0153] 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.

[0154] The first mechanical locking device 100 is implemented in Figures 3A-3C and 5A-5C. Figures 4A-4C An embodiment of a second mechanical locking device 100 ′ is shown.

[0155] The assembly process of a plurality of building panels 1, 1', 1" is Figure 2A and Figure 2B, 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 along 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 substantially 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.

[0156] Figure 3A , 3B 3C 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.

[0157] 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 substantially 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 substantially perpendicular to the front surface 8.

[0158] 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.

[0159] In the upper edge portion 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 undesired surface decoration.

[0160] 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.

[0161] Figure 4A , 4B 4C 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.

[0162] 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 substantially perpendicular to the front surface 8.

[0163] 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 4C The 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 substantially 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 4B , and locks two adjacent building panels 1, 1". in a direction at least substantially 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 substantially perpendicular to the front surface 8.

[0164] 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 substantially parallel to the front surface 8.

[0165] In an upper edge portion 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" in a direction essentially parallel to the front surface 8. 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 an optional bevel 10 is also advantageous. If the decorative layer of the surface layer 7 is a printed layer of any material, it may be particularly desirable to produce a desired transition between adjacent building panels 1, 1", 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 (e.g. floor, wall etc.), interruptions in the decorative surface may produce an undesirable surface decoration.

[0166] 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".

[0167] Figure 5A , Figure 5B and Figure 5C A cross section of two opposite 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 the adjacent building panel 1' instead of a folding displacement.

[0168] The mechanical locking device 100 is provided with a locking tongue 21 with a ridge 23 at a first edge 15 of a 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 an adjacent building panel 1'. The ridge 23 and the upper surface 32 of the tongue groove 31 are configured to lock 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 5B , and locks two adjacent building panels 1 , 1 ′ at least in a direction perpendicular to the front surface 8.

[0169] 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 .

[0170] 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 panels 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 panels 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 substantially parallel to the front surface 8. In the assembled position, the locking surface 25 of the locking groove 24 cooperates with or even contacts the locking surface 37 of the locking element 36, wherein the two locking surfaces 25, 37 produce a locking at least in a direction substantially parallel to the front surface 8.

[0171] In the upper edge portion 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 substantially 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.

[0172] 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.

[0173] Having a pressing slope (10) as described herein and in combination with Figures 4A-4C An advantage of the mechanical locking device 100 shown in Figures 5A-5C, 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". Then, the pressed bevel (10) with its seamless surface can 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.

[0174] Figure 6-13C Different possible arrangements of steps for processing the edges 15, 16, 17, 18 of the building panels 1 are shown, wherein Figure 6 The building panel 1 is shown with a substrate 3 and a surface layer 7 after being bonded together by pressure and preferably also by heating.

[0175] When the building panel 1 has a substrate 3 which does not deform plastically or at least does not deform plastically sufficiently, Figure 6-13C The arrangement of the finished edges 15, 16, 17, 18 of the building panels 1 shown is particularly advantageous. Figures 14A-14D and Figures 15A-15E A possible arrangement is shown for the final machining of the edges 15, 16, 17, 18 of a building panel 1 having a sufficiently plastically deformable substrate 3 to be deformed during pressing.

[0176] It is possible to form the bevel 10 along the edge of the building panel 1 directly after the building panel 1 has been formed by means of pressure and preferably also by means of heat, but in order to further ease the formation of the bevel 10, a process of producing notches 81a, 81b is performed. One possible way of producing notches 81a, 81b is in Figures 7A-7C Shown in.

[0177] In the process, the building panel 1 is preferably placed in or transported to the milling process 82 by a conveyor belt. The building panel 1 is typically processed with its substrate 3 facing upwards and its surface layer 7 facing downwards, but in alternative embodiments it can of course be processed the other way around, with its substrate 3 facing downwards and its surface layer 7 facing upwards.

[0178] 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 13A-13C .

[0179] 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.

[0180] In the example shown, each milling device 83a, 83b is configured to produce a notch 81a, 81b in the surface layer 7 at the edge portion 20, 20' mainly in the area close to the substrate 3, but in an alternative embodiment, a notch may be produced at least partially in the substrate 3 at the edge portion 20, 20'. The notch 81a, 81b may preferably be formed in the boundary between the surface layer 7 and the substrate 3 at the edge portion 20, 20'. The notch 81a, 81b may be formed in the surface layer and extend to at least 10%, at least 20% or at least 30% in the surface layer. In one embodiment, the notch 81a, 81b may be formed in the surface layer and extend to at least 90% in the surface layer.

[0181] One of the milling devices 83b is further configured to remove material from the substrate 3 in order to Figures 13A-13C The contemplated mechanical locking device 100 is shown in preparation.

[0182] The notches 81a, 81b are located at a distance from the front surface 8 in a direction substantially perpendicular to the front surface 8. The notches 81a, 81b may extend in a direction substantially parallel to the front surface 8 into the substrate 3, or into the surface layer 5, or into both.

[0183] The 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.

[0184] Fig. 8A and Figure 8B The next possible process is shown, namely a heating process 73. The heating process 73 is configured to heat the necessary areas along each edge of the building panel 1 to be able to form the bevel 10 at a later stage.

[0185] 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 heating and pressurizing 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.

[0186] 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.

[0187] Therefore, there are various possible arrangements for the manufacturing process, such as the bevel 10 being produced simultaneously when the building panel is formed by means of heat and pressure (described below), or the bevel 10 being 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 being 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 carried out without heating and only pressure is used to form the bevel 10.

[0188] However, in the heating process 73 shown, 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 of ​​the edge of the building panel 1 in which the chamfer 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 in which the chamfer 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 heat the area using IR or UV heating, hot air, laser, ultrasound or contact heat.

[0189] After the area has been heated in the heating process 73, the bevel 10 of the building panel 1 can be formed in a bevel forming process 75, see Figures 9A-9C The beveling process 75 may start with guiding the edge of the building panel 1 into the beveling process 75, for example by means of a guiding surface. The beveling process 75 is configured to bend the surface layer 7 from above (i.e. the surface facing upwards) or from below (i.e. the surface facing upwards) by pressing or shaping the surface layer 7 by means of shaping devices 77a, 77b (one shaping device is provided on each side of the building panel 1). Fig.9A and 9B The downwardly facing surface shown) forms the inclined surface 10. The forming means 77a, 77b may be a pressing means.

[0190] Each forming device 77a, 77b is configured to form and press the surface layer 7 and in some embodiments at least partially press the substrate 3 upwards (as it is processed in an upside-down manner). During the forming of the bevel 10, the forming devices 77a, 77b press the material or at least the surface layer 7 in the direction towards the notches 81a, 81b in the areas where each bevel on each side of the building panel 1 is to be formed, which areas may have been heated in a previous step. Thus, the volume of the notches 81a, 81b is reduced during the bevel forming process 75. Fig. 9C The formed inclined surface 10 and the notches 81a, 81b with reduced volumes are shown in FIG.

[0191] The notches 81 a , 81 b thus allow at least the surface layer 7 to be pressed against the substrate 3 , so that the chamfer 10 can be formed.

[0192] An alternative method (not shown) to the bevel forming process described above is to press / extrude the bevel 10 of the building panel 1 while forming the building panel itself and bonding the layers (i.e. substrate 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.

[0193] Fig. 10A and 10B A cooling process 79 is shown which is a preferred process step after forming the bevel 10 of the building panel 1. After and adjacent to the bevel forming process 75, a cooling process 79 is arranged for cooling the bevel 10 and the area in the edge in which the bevel 10 has been formed. 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.

[0194] 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.

[0195] The cooling process may be configured to reduce the temperature of the region 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 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.

[0196] Fig.11A and 11B , Fig. 12A and 12B as well as Fig.13A and 13B Three different types of finishing processes, ie final edge shaping processes, are shown that a building panel 1 may undergo.

[0197] Fig.11A and 11BA 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. 11B 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.

[0198] If the building panel 1 is machined by the first milling process and thereby produces notches 81a, 81b, the characteristic structures of the notches (e.g., gaps, etc.) are removed during the finishing process that produces the straight surfaces 92a, 92b of the edges. 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 of the building panel 1.

[0199] Fig. 12A and 12B 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, as shown in Fig. 17B. The surfaces 92a', 92b' of the edge extend in a direction inclining inwards 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.

[0200] If the building panel 1 is machined by the first milling process and thereby produces notches 81a, 81b, the characteristic structure of the notches (e.g., gaps, etc.) is removed during the finishing process of producing the inclined surfaces 92a', 92b' of the edges. 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 of the building panel 1.

[0201] Figures 13A-13C A 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 13A-13C 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. 13C One type of mechanical locking device 100 is shown. Figures 3A-5COther 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 ″.

[0202] If the building panel 1 is also machined by the first milling process and thereby the notches 81a, 81b are produced, the characteristic structures of the notches (e.g., gaps, etc.) are removed during the finishing process that produces the mechanical locking devices 100, 100'. 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.

[0203] Figures 14A-14D Shown with reference Figure 6-13C A cross section of a building panel 1 which is finished in a slightly different way than described is shown. 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.

[0204] Fig.14A Shown is a cross section of a building panel 1 before final processing with a substrate 3 and a surface layer 7 after being bonded together by pressure and preferably also by heating.

[0205] Fig. 14B A cross section of a building panel 1 is shown after a process of producing notches 81a, 81b. The notches 81a, 81b are produced such that their position is suitable for a later intended finishing process of the edge. In this example, the later intended finishing process is a process of producing mechanical locking means, and therefore the notches 81a, 81b are produced at positions matching the intended mechanical locking means.

[0206] If you can Fig. 14B As can be seen in FIG. 1 , the notches 81a, 81b are partially or entirely produced in the substrate 3. The notches 81a, 81b are partially or entirely produced in the substrate 3 at the edge portion. 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 where the bevel of the building panel 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 immediately transferring the building panel from the forming process when at least the area between the notches 81a, 81b and the surface where the bevel is to be formed is still sufficiently hot.

[0207] Fig. 14CA 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 indentation 81a, 81b has been reduced because material from the area between the indentation 81a, 81b and the surface in which the bevel has now been formed has been pressed into the indentation 81a, 81b. Thus, the shape of each indentation 81a, 81b has changed. The bevel 10 may be formed by applying pressure to the upper edge portion thereby pressing the edge portion of the surface layer 5 towards the indentation 81a, 81b. The bevel 10 may be formed according to the above reference to Figures 9A-9C The method described is formed.

[0208] Fig.14D A cross section of a building panel 1 after a finishing process is shown, wherein a mechanical locking means 100 has been produced in the edge of the building panel 1. After the beveling process, the remaining notches 81a, 81b have been removed during the finishing process producing the mechanical locking means 100. Furthermore, a bevel 10 of the desired length has been produced by the finishing process.

[0209] Figures 15A-15E Shown with reference Figure 6-13C and Figures 14A-14D A cross section of a building panel 1 which is finished in a slightly different way than described is shown. An alternative possible arrangement for the finishing of the building panel 1 is suitable when having a substrate 3 which is sufficiently plastically deformable under the influence of pressure and preferably also heat.

[0210] Fig.15A Shown is a cross section of a building panel 1 before final processing with a substrate 3 and a surface layer 7 after being bonded together by pressure and preferably also by heating.

[0211] Fig. 15B A cross section of a building panel 1 is shown after a process of producing notches 81a, 81b. In this example, the notches 81a, 81b are substantially similar and are arranged at similar positions along respective edges of the building panel 1. The notches 81a, 81b are produced such that their positions are suitable for a later intended edge finishing process. In this example, the later intended finishing process is a process producing a straight or angled surface, so the notches 81a, 81b are produced at positions matching these types of surfaces.

[0212] from Fig. 15BAs can be seen in the figure, the notches 81a, 81b are completely / entirely produced in the substrate 3. The notches 81a, 81b are completely produced in the substrate 3 at the edge portions. To form the bevel 10, it may be necessary to sufficiently heat the building panel 1 in the area between the notches 81a, 81b and the surface of the building panel in which the bevel 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 immediately transferring the building panel from the forming process when at least the area between the notches 81a, 81b and the surface in which it is to be formed is still sufficiently hot.

[0213] Fig. 15C 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 indentation 81a, 81b has been reduced because material from the area between the indentation 81a, 81b and the surface in which the bevel has now been formed has been pressed into the indentation 81a, 81b. Thus, the shape of each indentation 81a, 81b has changed. The bevel 10 may be formed by applying pressure to the upper edge portion thereby pressing the edge portion of the surface layer 5 towards the indentation 81a, 81b. The bevel 10 may be formed according to the above reference to Figures 9A-9C The method described is formed.

[0214] Fig.15D shows a cross section of a building panel 1 after the finishing process, wherein preferably the Fig.11A The process described produces a straight surface in the edge of the building panel 1. After the beveling process, the remaining notches 81a, 81b have been removed during the finishing process that produced the surface, such as by means of Figures 15C-15E Furthermore, the desired length of the bevel 10 has been produced by the finishing process.

[0215] Fig.15E A cross section of a building panel 1 is shown after an alternative finishing process, wherein preferably the Fig. 12A The process described produces an angled / sloped surface in the edge of the building panel 1. After the beveling process, the remaining notches 81a, 81b have been removed in the finishing process that produced the surface, such as by means of Figures 15C-15E Furthermore, the desired length of the bevel 10 has been produced by the finishing process.

[0216] In the above embodiment, the bevel 10 may be provided with embossing or structure. In one embodiment, the forming device 77a, 77b for forming the bevel 10 may be configured to press the embossed pattern or structure into the bevel during the formation of the bevel. For example, it may be desirable to have 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.

[0217] 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.

Claims

1. A method for producing a bevel (10) at least partially along at least one edge (15, 16, 17, 18) of a building panel (1), such as a floor panel or a wall panel, wherein the building panel (1) comprises a polymer-based material, the method comprising: creating a notch (81a, 81b) in an edge portion (20, 20') of the at least one edge (15, 16, 17, 18) of the building panel (1), wherein the notch (81a, 81b) is located at a distance from the surface (8) of the building panel (1) in a direction substantially perpendicular to the surface (8) of the building panel (1) in which the bevel (10) is to be formed; heating at least the area between the notch (81a, 81b) and the surface (8) of the building panel (1) in which the bevel (10) is to be formed; Pressure is applied to the surface (8) to form a bevel (10) of the building panel (1).

2. The method according to claim 1, wherein: The polymer based material of the building panel (1) is a thermoplastic material.

3. The method according to claim 2, wherein: The building panel (1) comprises thermoplastic material in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

4. A method according to any one of the preceding claims, wherein: The building panel (1) comprises a surface layer (7) and a substrate (3) comprising a polymer-based material, wherein the surface layer (7) comprises a decorative layer (12).

5. The method according to claim 4, wherein: The decorative layer is a printed polymer-based sheet.

6. The method according to claim 4 or 5, wherein: The surface layer (7) further comprises a wear-resistant layer (13).

7. The method according to any one of claims 4 to 6, wherein: The polymer-based material of the substrate (3) is a thermoplastic material.

8. The method according to claim 7, wherein: The substrate (3) comprises thermoplastic material in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%.

9. The method according to any one of claims 4 to 8, wherein: The notches (81a, 81b) are at least partially located in the base plate (3).

10. The method according to any one of claims 4 to 9, wherein: The indentations (81a, 81b) are at least partially located in the surface layer (7).

11. A method according to any one of the preceding claims, wherein: The notch (81a, 81b) extends along the entire length of the at least one edge (15, 16, 17, 18) of the building panel (1).

12. A method according to any one of the preceding claims, wherein: The notch (81a, 81b) extends into an edge portion (20, 20') of the at least one edge (15, 16, 17, 18) in a direction substantially parallel to the surface (8) of the building panel (1).

13. The method according to any one of the preceding claims, further comprising: The bevel (10) is cooled at least partially in a region between the recess (81a, 81b) and the surface (8) of the building panel (1) by means of a cooling device.

14. The method according to claim 13, wherein: Cooling occurs during application of pressure to the surface (8) to form the bevel (10) of the building panel (1).

15. A method for manufacturing a building panel (1), such as a floor panel or a wall panel, wherein the building panel (1) comprises a polymer-based material, the method comprising: applying a surface layer (7) onto a substrate (3), wherein the surface layer (7) comprises a decorative layer (12); applying pressure to form a 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) using a method according to any one of claims 1 to 14.

16. The method according to claim 15, wherein: Applying pressure to form the building panel (1) also includes applying heat.

17. The method according to claim 15 or 16, 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).

18. The method according to claim 17, wherein: The notch (81a, 81b) is temporary and is not present after finishing the at least one edge (15, 16, 17, 18) of the building panel (1).

19. The method according to claim 17 or 18, wherein: Finishing the at least one edge (15, 16, 17, 18) of the building panel (1) comprises producing a mechanical locking device (100, 100') 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.

20. The method according to any one of claims 15 to 19, further comprising: Before applying the surface layer (7) to the substrate, an adhesive is applied to the substrate (3) so that the adhesive is arranged between the substrate (3) and the surface layer (7); or, before applying the surface layer to the substrate (3), an adhesive is applied to the surface layer (7) so that the adhesive is arranged between the substrate (3) and the surface layer (7).

Images