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 substrate (3) having an amount of an inorganic filler and a polymer-based material in the range of 50-85 wt%. The method comprises: heating at least an edge portion of an edge of the building panel (1) along which an inclined surface will be formed; and forming a bevel in the edge portion by applying pressure to the portion, wherein the bevel is at least partially formed in the substrate (3).

Description

Technical Field

[0001] The application relates to the field of building panels and in particular the application relates to a method of producing a bevel on a building panel with a high filler content. 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 50-85 weight % (wt%) inorganic fillers such as chalk. LVT panels typically have an elastic modulus of less than 2000 MPa because they often contain plasticizers in amounts of 1-20 wt%.

[0004] However, known techniques for producing desired building panels present difficulties as to how to produce desired embossings or bevels on such building panels. Summary of the invention

[0005] It is an object of at least one embodiment of the present invention to provide an improvement over the known technology. This object is achieved by the technology defined herein.

[0006] In a first aspect of the inventive concept, 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 substrate and a surface layer, the substrate comprising an inorganic filler and a polymer-based material in an amount of 50-85 wt%, the method comprising:

[0007] heating at least an edge portion of an edge of the building panel along which the bevel is to be formed; and

[0008] A chamfer is formed in the portion by applying pressure to the edge portion, wherein the chamfer is at least partially formed in the substrate.

[0009] A bevel may be formed in the edge portion.The bevel may extend at least partially along the at least one edge of the building panel.

[0010] 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.

[0011] 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.

[0012] The bevel may further be curved with a radius of 1 mm to 10 mm.

[0013] 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.

[0014] Heating at least the edge portion of the building panels may be performed by at least one of an IR heating device, a hot air device, a UV heating device, a laser device, an ultrasound device or a contact heating device.

[0015] In one embodiment, when the bevel is formed, the temperature of the material of the edge portion is 40-220° C., or 75-180° C., and it may depend on various characteristics, such as the thickness of the material, the type of the material.

[0016] 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 in the material when the bevel is formed.

[0017] 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 decorative layer in the bevel.

[0018] 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 panel, so as mentioned above, the surface of the building panel is usually the front surface of the building panel. However, it can alternatively be the back surface of the building panel.

[0019] In one embodiment, the method further comprises cooling the bevel. 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 thereby the final appearance of the bevel of the building panel. 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.

[0020] Cooling can be performed while the bevel is being formed, or cooling the bevel can be performed separately from forming the bevel.

[0021] Cooling may be performed by at least one means using air, water, oil, a radiator, or a combination thereof.

[0022] 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.

[0023] 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.

[0024] In one embodiment, the substrate comprises the filler in an amount of 60-85 wt%.

[0025] In another embodiment, the substrate comprises the filler in an amount of 70-85 wt%.

[0026] The filler may be an inorganic filler selected from calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

[0027] The filler may comprise less than 10 wt% organic material, such as wood-based material or cellulose-based material, or less than 5 wt% organic material, such as 0.5-10 wt% organic material. In one embodiment, the filler comprises 0% organic material.

[0028] Furthermore, the substrate may have a thermal conductivity of at least 0.4 W / mK, at least 0.5 W / mK, or at least 0.6 W / mK.

[0029] In one embodiment, the polymer-based material of the substrate is a thermoplastic material.

[0030] The thermoplastic material of the substrate may 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.

[0031] The substrate material may comprise the thermoplastic material in an amount of at least 7 wt%, at least 10 wt% or at least 15 wt%.

[0032] The substrate is configured to be at least partially plastically deformable when pressure is applied so as to form at least the inclined surface of the building panel.To make the substrate plastically deformable, the material may comprise a plasticizer or comprise at least two different types of polymers, as described below.

[0033] Thus, the substrate may further comprise 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 may comprise a plasticizer in an amount of 1-30 wt% or 2-15 wt%.The plasticizer provides the substrate with desirable formable properties.

[0034] Another method of producing the desired formable properties of the substrate material is that the substrate material 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 material blend of the substrate may be 1-20%, and the PVC content in the material blend may be 80-99%.

[0035] The substrate may be a single-layer substrate or a multi-layer substrate.

[0036] In one embodiment, the method further comprises:

[0037] Before the step of heating at least the edge portion, a notch is formed in the 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.

[0038] The indentation may be at least partially formed in the substrate.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] In another embodiment, the height of the opening of the notch before the bevel is formed exceeds the height of the bevel.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] In an alternative embodiment, the indentations may be located at a distance from the surface of the building panel in a direction substantially perpendicular to the surface of the building panel. If the surface is the front surface of the building panel, the distance from the surface of the building panel may preferably correspond at least to the thickness of the surface layer of the building panel 1. In one embodiment, the indentations are arranged in the substrate of the building panel and in an alternative embodiment the indentations are arranged partly in the substrate and partly in the surface layer.

[0049] In one embodiment the notch extends along the entire length of the edge of the building panel in which the notch is created.

[0050] The characteristics and dimensions of the notch may vary depending on, for example, the material of the layer in which the notch is created, the intended size of the bevel, or the intended finishing process, for example in case the building panels shall comprise mechanical locking means.

[0051] In one embodiment the step of heating at least an edge portion of an edge of the building panel comprises heating at least an area between the notch and the surface of the building panel in which the bevel is to be formed.

[0052] In one embodiment the building panel further comprises a surface layer comprising a decorative layer. The decorative layer may be a coloured 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).

[0053] In another embodiment, the decorative layer of the surface layer is a printed polymer-based sheet.

[0054] Furthermore, the surface layer of the building panels 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.

[0055] The method may further include:

[0056] After forming the bevel along the 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 by cutting, milling and / or grinding, for example.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] The notch is preferably a temporary feature of the building panel edge which no longer assumes its original shape after the finishing process.

[0061] The method may further include:

[0062] Along at least one edge of the building panels a mechanical locking device is created, wherein the mechanical locking device is configured for locking similar or substantially identical building panels horizontally and / or vertically in an assembled position.

[0063] Producing mechanical locking devices can be seen as another example of finishing building panel edges.

[0064] 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.

[0065] 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.

[0066] In a second aspect of the inventive concept, there is provided a method for manufacturing a building panel, such as a floor panel or a wall panel, the method comprising:

[0067] applying a surface layer to a substrate, wherein the substrate comprises a polymer-based material and an inorganic filler in an amount of 50-85 wt %;

[0068] applying heat and pressure to form building panels; and

[0069] A bevel is formed along at least one edge of a building panel using a method according to any of the embodiments above.

[0070] The pressure applied when forming the building panels may be 5-20 bar.

[0071] The temperatures applied when forming building panels may be 120-160°C.

[0072] In a third aspect of the inventive concept, there is provided a building panel, such as a floor panel or a wall panel, comprising:

[0073] A substrate comprising a polymer-based material and an inorganic filler in an amount of 50-85 wt %;

[0074] A surface layer including a decorative layer and a wear-resistant layer; and

[0075] a bevel extending along at least one edge of a building panel,

[0076] The inclined surface is manufactured by a method according to any of the above embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] 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.

[0078] Figure 1A is a schematic perspective view of a building panel according to an embodiment of the present inventive concepts;

[0079] Figure 1B is a schematic top view of a building panel according to an embodiment of the present inventive concepts;

[0080] Figure 2A schematically illustrates an assembly of a plurality of building panels;

[0081] Figure 2B Schematically shows Figure 2A Finished components;

[0082] 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;

[0083] Figure 3B Schematically shows the assembled position Figure 3A A cross section of two opposite edge portions of;

[0084] Figure 3C Schematic diagram showing the assembly process Figure 3A A cross section of two opposite edge portions;

[0085] 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 another embodiment of the inventive concept;

[0086] Figure 4B Schematically shows the assembled position Figure 4A A cross section of two opposite edge portions of;

[0087] Figure 4C Schematic diagram showing the assembly process Figure 4A A cross section of two opposite edge portions;

[0088] 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;

[0089] Figure 5B Schematically shows the assembled position Figure 5A A cross section of two opposite edge portions of;

[0090] Figure 5C Schematic diagram showing the assembly process Figure 5A A cross section of two opposite edge portions;

[0091] 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;

[0092] 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;

[0093] Figure 7B yes Fig. 7A Detailed view of

[0094] Figure 7C Schematically shows the Fig. 7A a side view of a cross section of the building panel after step one of;

[0095] 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;

[0096] Figure 8B yes Fig. 8A Detailed view of

[0097] Fig.9A Schematically illustrates step three of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0098] Fig. 9B yes Fig.9A Detailed view of

[0099] Fig. 9C Schematically shows the Fig.9A a side view of a cross section of the building panel after step three in;

[0100] 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;

[0101] Fig. 10B yes Fig. 10A Detailed view of

[0102] 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;

[0103] Fig. 11B Schematically shows the Fig.11A a side view of a cross section of a building panel after the steps in;

[0104] 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;

[0105] Fig. 12B Schematically shows the Fig. 12A a side view of a cross section of a building panel after the steps in;

[0106] Fig.13A showing steps of yet another finishing method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0107] Fig. 13B yes Fig.13A Detailed view of

[0108] Fig. 13C Schematically shows the Fig.13A a side view of a cross section of a building panel after the steps in;

[0109] Fig.14ASchematically illustrates step one of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0110] Fig. 14B yes Fig.14A Detailed view of

[0111] Fig. 14C Schematically shows the Fig.14A a side view of a cross section of the building panel after step one of;

[0112] Fig.15A Schematically illustrates step two of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0113] Fig. 15B yes Fig.15A Detailed view of

[0114] Fig.16A Schematically illustrates step three of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0115] Fig. 16B yes Fig.16A Detailed view of

[0116] Fig. 16C Schematically shows the Fig.16A a side view of a cross section of the building panel after step three in;

[0117] Fig.17A schematically illustrates step four of a method for producing a desired edge of a building panel according to an embodiment of the inventive concept;

[0118] Fig. 17B yes Fig.17A Detailed view of

[0119] Fig.18A Schematically shows an embodiment of the present invention. Fig. 17B a side view of a cross section of a building panel after the steps of the method shown;

[0120] Fig.18B Schematically shows a method for producing a substantially straight surface of a building panel according to an embodiment of the inventive concept after the steps of the finishing method Fig.18A A side view of a cross section in FIG.

[0121] Fig.18C Schematically shows a method for producing an inclined surface of a building panel according to an embodiment of the inventive concept after the steps of the finishing method Fig.18A a side view of a cross section in FIG. 1 ; and

[0122] Fig.19 is a graph showing the results of one embodiment. DETAILED DESCRIPTION

[0123] 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 the present 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. Generally, in the present disclosure, terms like "below" or "lower" generally mean closer to the rear surface of the panel or its plane, while "above" or "upper" means 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, the 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 involve the direction substantially parallel to the extension of the decorative surface and the direction substantially perpendicular to the extension of the decorative surface. When the building panel is laid flat on, for example, the 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.

[0124] 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 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.

[0125] 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.

[0126] 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.

[0127] 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. The method can also 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 can be a glue.

[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 has 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 is 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] The substrate 3 may include a substrate material comprising a polymer-based material, which is preferably a thermoplastic material. The thermoplastic material may be selected from the group comprising 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 a combination thereof. The substrate material may include a thermoplastic material in an amount of at least 7wt%, at least 10wt%, or at least 15wt%.

[0133] The substrate material may preferably comprise less than 10 wt% wood-based material, or less than 5 wt% wood-based material, such as 0.5-10 wt% wood-based material.

[0134] The substrate material may also include one or more inorganic fillers, such as calcium carbonate (CaCO 3 ), barium sulfate (BaSO 4 ), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

[0135] The filler may comprise less than 10 wt% organic material, such as wood-based material or cellulose-based material, or less than 5 wt% organic material, such as 0.5-10 wt% organic filler. In one embodiment, the filler comprises 0% organic material.

[0136] The substrate contains the filler in an amount of 50-85 wt %.

[0137] Furthermore, the substrate has a thermal conductivity of at least 0.4 W / mK, at least 0.5 W / mK or at least 0.6 W / mK. The higher the thermal conductivity of the material, the shorter the time required to heat the area before pressing, for example, a bevel, which makes the manufacturing process more efficient and less time-consuming. For example, some tests are given below showing the correlation between the amount of filler and the thermal conductivity of a suitable substrate.

[0138] These types of inorganic fillers are particularly cost-effective and readily available.

[0139] The substrate material further comprises a plasticizer, which is preferably 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 one way of making the substrate 3 more susceptible to plastic deformation under the influence of pressure and preferably also heat.

[0140] Another way to make the substrate 3 plastically deform under the influence of 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% and the PVC content in the material blend may be 80-99%.

[0141] 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.

[0142] In one embodiment, the substrate material consists of a plastisol.

[0143] The substrate 3 preferably has a thickness of 1-10 mm, a thickness of 2-8 mm, or a thickness of 3-7 mm.

[0144] A surface layer 7 is arranged on the substrate 3 above the substrate 3. The upper side of the surface layer 7 forms the front surface 8 of the building panel 1 .

[0145] 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 12 and a wear-resistant layer 13, wherein the decorative layer 12 is arranged between the substrate 3 and the wear-resistant layer 13, and the wear-resistant layer 13 is the uppermost layer of the building panel 1.

[0146] The decorative layer 12 may be a colored powder layer, paper, polymer-based board material, wood-based board material, wood veneer layer, cork-based board material or fabric (woven fabric or non-woven fabric). The decorative layer 12 may also be a printed layer, such as a printed polymer-based board material.

[0147] The wear-resistant layer 13 may be a wear-resistant foil, a wear-resistant layer with wear-resistant particles and / or a paint layer and / or a coating. The wear-resistant layer is preferably a transparent layer, ie a layer that does not affect the appearance of the decorative layer 12 arranged below.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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 a rectangular building panel, but it is of course optional and equally feasible to have bevels 10 along the long sides of the building panel 1.

[0152] The upper part 20 is located at the front of the building panel 1 and may comprise the surface layer 7 and at least part of the substrate 3. If desired, the bevel may also be arranged along the third and fourth edges. The bevel 10 extends 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.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] Figure 3A , 3B3C 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.

[0158] 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.

[0159] 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.

[0160] 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 undesired surface decoration.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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 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 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.

[0165] 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.

[0166] 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.

[0167] 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".

[0168] 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.

[0169] 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.

[0170] 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 .

[0171] 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.

[0172] 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.

[0173] 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.

[0174] Having a pressing bevel 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". 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.

[0175] 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. Figures 14A-17B Another possible arrangement of steps for machining the edges 15 , 16 , 17 , 18 of the building panels 1 is shown.

[0176] When the building panel 1 has a substrate 3 which is plastically deformable under pressure, Figure 6-13C and Figures 14A-17BThe arrangement of the finished edges 15, 16, 17, 18 of the building panels 1 shown is particularly advantageous.

[0177] 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. Two possible ways of producing notches 81a, 81b are Figures 7A-7C and Figures 14A-14C Shown in.

[0178] 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 in the other way around, with its substrate 3 facing downwards and its surface layer 7 facing upwards.

[0179] 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. The aim is that the notch 81a, 81b will not affect or interfere with the proportions, shape and function of the mechanical locking device 100, 100' to be formed later, see Figures 13A-13C .

[0180] 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.

[0181] Each milling device 83a, 83b is configured to produce a notch 81a, 81b at the edge portion 20, 20', but if desired, also in the surface layer 7. One of the milling devices 83b is further configured to remove material from the substrate 3 at the edge portion 20, 20' in order to provide a 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 into the substrate 3 in a direction substantially parallel to the front surface 8, or into both the substrate 3 and the surface layer 5.

[0183] Figures 8A-8B and Figures 15A-15B 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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.

[0188] 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 and Figures 16A-16CThe 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). Figures 9A-9B and Figures 16A-16C The downwardly facing surface shown) forms the inclined surface 10. The forming means 77a, 77b may be a pressing means.

[0189] 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 material in the direction towards the notches 81a, 81b in the area 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. As a result, the volume of the notches 81a, 81b is reduced during the bevel forming process 75. Fig. 9C and Fig. 16C The formed inclined surface 10 and the notches 81a, 81b with reduced volumes are shown in FIG.

[0190] The notches 81a , 81b thereby allow the surface layer 7 and at least part of the substrate 3 to be pressed towards the rear surface 4 of the building panel 1 so that the chamfer 10 can be formed.

[0191] 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.

[0192] Fig.17A and 17B A cooling process 79 is shown which is a preferred process step after or during forming the bevel 10 of the building panel 1. If performed after forming the bevel 10, this cooling process 79 is arranged near the bevel forming process 75 for cooling the bevel 10 and the area in the edge where 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.

[0193] Fig.11A and11B , 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.

[0194] The notches 81a, 81b may preferably be temporary features of the edge 15, 16, 17, 18 of the building panel 1 which no longer assume their original shape after the finishing process.

[0195] Fig.11A and 11B 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. 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.

[0196] If the building panel 1 is machined by the first milling process and thus the notches 81a, 81b are produced, the characteristic structure of the notches (e.g., 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.

[0197] exist Fig.18A and 18B The cross section after the bevel is formed is shown in FIG. Fig.11A and 11B Comparison between cross sections after the described finishing process.

[0198] 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, 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.

[0199] If the building panel 1 is machined by the first milling process and thereby produces the notches 81a, 81b, the characteristic structure (e.g., gap, etc.) of the notches no longer exists after the finishing process that produces the inclined 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.

[0200] exist Fig.18A and 18C The cross section after the bevel is formed is shown in FIG. Fig. 12A and 12B Comparison between cross sections after the described finishing process.

[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-5C 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 ″.

[0202] If the building panel 1 is also machined by the first milling process and the notches 81a, 81b are thereby produced, the characteristic structure of the notches (e.g., gaps, etc.) no longer exists after 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] 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.

[0204] Example

[0205] To measure the thermal conductivity of the layer, a thermal conductivity analyzer TCi from C-therm (model / serial #TH91-13-00729 with sensor H461) was used. The test was performed by placing three drops of water onto the sensor with a pipette, then placing the sample in the center of the sensor and placing a 500 g weight on top to ensure that the sample stayed in place during the measurement. After that, the test began. Ten measurements were performed for each sample.

[0206] Example: Substrate with thermoplastic material and inorganic filler

[0207] To measure the thermal conductivity of the substrate, a thermal conductivity analyzer TCi from C-therm (model / serial #TH91-13-00729 with sensor H461) was used. The test was performed by placing three drops of water onto the sensor with a pipette, then placing the sample in the center of the sensor and placing a 500g weight on top to ensure that the sample stayed in place during the measurement. After that, the test began. Ten measurements were performed for each sample.

[0208] For testing, PVC blends or PP blends were mixed with different fillers in different amounts. The PVC blend formulations are defined in Table 1 and the PP blend formulations are defined in Table 2.

[0209] Table 1: PVC blend formulations

[0210]

[0211] Table 2: PP blend formulation

[0212]

[0213] According to Table 1, 300 g of the PVC blend was mixed with calcium carbonate (CaCO3), an inorganic filler commonly used in products such as building panels, and according to Table 2, 300 g of the PP blend was mixed with calcium carbonate (CaCO3), with talc, or with a mixture of calcium carbonate (CaCO3) and a gas-containing element. The gas-containing element can be, for example, These are polymer-based spheres or microspheres that contain a gas that expands upon heating or glass-based bubbles that can contain air in this test.

[0214] Table 3 gives the correlation between the amount of the above fillers in the substrate and the thermal conductivity of this substrate.

[0215] Table 3: Relationship between thermal conductivity of substrates with PVC blends or PP blends and different fillers

[0216] substrate Weight % of filler Thermal conductivity [W / mK] <![CDATA[PVC blend + CaCO3]]> 14 0.266 <![CDATA[PVC blend + CaCO3]]> 25 0.288 <![CDATA[PVC blend + CaCO3]]> 40 0.492 <![CDATA[PVC blend + CaCO3]]> 50 0.600 PP blend + talc 50 0.566 <![CDATA[PP blend + CaCO3]]> 50 0.59 <![CDATA[PP blend + CaCO3 and glass bubbles]]> <![CDATA[25(CaCO3)+25(glass bulb)]]> 0.42

[0217] By studying the results in Table 3, it is concluded that more CaCO3 filler increases the thermal conductivity, which is preferred for substrates, as mentioned above. Another conclusion is that there is a correlation between the amount of CaCO3 filler in the PVC blend and the thermal conductivity, as shown in Fig.19 shown.

[0218] 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 substrate (3) and a surface layer (7), the substrate comprising a polymer-based material and an inorganic filler in an amount of 50-85 wt.%, the method comprising: heating at least an edge portion (20, 20') of an edge (15, 16, 17, 18) of the building panel (1) along which the bevel (10) is to be formed; and The bevel (10) is formed in the portion by applying pressure to the edge portion (20, 20'), wherein the bevel (10) is at least partially formed in the substrate (3).

2. The method according to claim 1, wherein: Heating at least the edge portion (20, 20') of the building panel (1) is performed by at least one of an infrared heating device, a hot air device, an ultraviolet heating device, a laser device, an ultrasonic device or a contact heating device.

3. The method according to claim 1 or 2, further comprising: The inclined surface (10) is cooled.

4. The method according to claim 3, wherein: Cooling is performed while the inclined surface (10) is formed.

5. The method according to claim 3, wherein: Cooling the bevel (10) is performed separately from forming the bevel (10).

6. The method according to any one of claims 3 to 5, wherein: The cooling is performed by at least one means using air, water, oil, a radiator, or a combination thereof.

7. A method according to any one of the preceding claims, wherein: The substrate (3) contains fillers in an amount of 60-85 wt% or 70-85 wt%.

8. A method according to any one of the preceding claims, wherein: The inorganic filler is selected from calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, gas-containing elements such as glass bubbles, and / or combinations thereof.

9. A method according to any one of the preceding claims, wherein: The substrate (3) has a thermal conductivity of at least 0.4 W / mK, at least 0.5 W / mK or at least 0.6 W / mK.

10. The method according to any one of the preceding claims, further comprising: Prior to the step of heating at least the edge portion (20, 20'), a notch (81a, 81b) is produced in the 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 perpendicular to the surface (8) of the building panel (1) in which the chamfer (10) is to be formed.

11. The method according to claim 10, wherein: The recesses (81a, 81b) are at least partially produced in the substrate (3).

12. The method according to claim 10 or 11, wherein: The step of heating at least an edge portion (20, 20') of an edge (15, 16, 17, 18) of the building panel (1) comprises heating at least an area between the notch (81a, 81b) and a surface (8) of the building panel (1) in which the bevel (10) is to be formed.

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

14. A method according to any one of the preceding claims, wherein: The surface layer (7) comprises a printed polymer substrate.

15. A method for manufacturing a building panel (1), such as a floor panel or a wall panel, the method comprising: applying a surface layer (7) onto a substrate (3), wherein the substrate comprises a polymer-based material and an inorganic filler in an amount of 50-85 wt%; applying heat and pressure to form said building panel (); 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. A building panel, such as a floor panel or a wall panel, comprising: A substrate (3) comprising a polymer-based material and an inorganic filler in an amount of 50-85 wt %; A surface layer (7) comprising a decorative layer (12) and a wear-resistant layer (13); and a bevel (10) extending along at least one edge (15, 16, 17, 18) of the building panel (1), The inclined surface is manufactured by the method according to any one of claims 1 to 14.

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