Panel and method for designing and manufacturing such panel

Abstract

A panel (10) for forming a covering is provided having a first pair of opposing edges (14, 15) and a second pair of opposing edges (56, 57). The first pair of opposing edges (14, 15) and the second pair of opposing edges (56, 57) comprise coupling portions, the contoured structure of at least one of the coupling portions of the first pair of opposing edges (14, 15) being provided with a cutout (22, 35) such that a residual segment (30, 31) located at a corner of the panel (10) is prevented from being formed or removed. A method for designing a panel (10) is provided in which the formation of a residual segment at a corner is prevented or the residual segment is removed. A method for manufacturing a panel (10) is provided in which the formation of a residual segment at a corner is prevented or removed by adding a cut-out (22, 35) to the profile of at least one coupling portion of a first pair of opposing edges (14, 15) or by vertical movement of a milling tool.

Description

Technical Field

[0001] The present disclosure generally relates to a panel, a method for manufacturing such a panel, and a method for designing such a panel.

[0002] More particularly, the present disclosure relates to a panel having a first pair of opposing edges and a second pair of opposing edges, the panel including a coupling portion on one of the edges that allows the panel to be coupled to another similar panel, the coupling portion also being adapted to prevent the formation of a residual segment or to remove a residual segment. Background Art

[0003] Such panels are known, for example, from WO 97 / 47843. In this case, rectangular floor panels are provided with long and short edges. A coupling portion at one of the long edges is configured to cooperate with a coupling portion at the other long edge of another similar panel. A coupling portion at one of the short edges is configured to cooperate with a coupling portion at the other short edge of another similar panel. As is well known, such coupling portions can be formed using a conventional tongue-and-groove connection, wherein these coupling portions can be glued into one another when the floor panels are installed, or using mechanical coupling portions, thereby providing for interlocking of the floor panels in both horizontal and vertical directions. The cooperation between the tongue and groove creates a vertical interlock. The horizontal interlock is achieved by the engagement of an interlocking lip with a downwardly directed interlocking groove.

[0004] WO 97 / 47834 describes how respective coupling portions situated on two opposite sides can be formed in a continuous machine (in other words, while the panel is moved on a rotating mechanical cutting tool). This method is also referred to as "continuous milling". In the case where the profile structure is to be applied on all four sides, the panel can be displaced using two perpendicular movements, whereby during a first movement the profile structure is provided at two opposite edges (in this case the longitudinal edges) using milling devices positioned at different angles relative to or in relation to the panel. Conversely, during a second movement the profile structure is provided at the other edges (in this case the small edges) by further milling devices positioned at different angles relative to the panel. During each of the above-mentioned milling cycles, the final form of the tongue or groove is preferably achieved essentially on one side.

[0005] Similar panels allow for connection using contoured edges, such as basic click panels, drop-down click panels, and other panels arranged to fold down (i.e., fold-down type). As described in WO 97 / 47834, contoured edges are typically made into connection portions using milling tools. However, a common problem is that when the connection portions have different sizes, there may be residual portions at the corners of such panels. At least in these cases, after the second pair of opposing edges are milled, residual segments may remain at the corners. Such residual segments may cause problems in subsequent production steps, for example, when coating agents, impregnants, paints, etc. are applied to the edges of the panels. In particular, the residual segments may become loose at the height of the machines of the subsequent production steps and may clog the nozzles of these machines, contaminate the material being applied, or otherwise interrupt the intended production.

[0006] To compensate for this shortcoming, the use of so-called additional jumpers to cut these pieces has been considered. As is known in milling technology, a jumper is a tool that performs a cutting or moving motion toward the edge of the panel at the appropriate time to cut off or knock off residual sections, such as those at corners. The use of a jumper or related device necessarily requires the use of additional machinery in the milling process, requiring additional space and expense in the assembly manufacturing process. Furthermore, extremely precise positioning is required to prevent the jumper from damaging the joint. Summary of the Invention

[0007] It is an object of the present disclosure to provide solutions to one or more problems encountered with prior art panels and related processes.

[0008] According to a first aspect, the present disclosure relates to a method for manufacturing a panel, which method allows obtaining a better and / or cheaper and / or more flexible and / or more reliable finishing of the joining portion on the edge of the panel. The disclosure also relates to a method for designing such a panel and a panel obtained by such a method.

[0009] In one aspect, the present disclosure relates to a panel for forming a covering, the panel having an upper side defining an upper plane and an opposing lower side. The panel may include a first pair of opposing edges and a second pair of opposing edges. The first pair of opposing edges may be provided with a coupling portion in the form of a tongue at one of the first pair of opposing edges and a groove at the other of the first pair of opposing edges. The groove may be defined by an upper lip and a lower lip, wherein the lower lip extends distally beyond the upper lip. The second pair of opposing edges may be provided with a coupling portion in the form of a male coupling portion at one of the second pair of opposing edges and a female coupling portion at the other of the second pair of opposing edges. The tongue may include a recess opposite the upper side of the panel and configured to receive a portion of the lower lip in a coupled state. Preferably, the lower lip includes an upwardly directed interlocking portion, wherein the recess is configured to receive the upwardly directed interlocking portion. The upwardly directed interlocking portion preferably forms a distal portion of the lower lip. Thus, the panel may form an interlocking tongue-and-groove connection between one of the first pair of opposing edges of the panel and another edge of a similar panel (e.g., the other edge of the first pair of opposing edges of the similar panel).

[0010] The convex coupling portion at one edge of the second pair of opposite edges and the concave coupling portion at the other edge of the second pair of opposite edges can be in the form of a tongue and groove, wherein the groove can be delimited by an upper lip and a lower lip, wherein the lower lip extends distally beyond the upper lip. Thus, the two panels can be coupled to each other at the height of the corresponding first pair of opposite edges by flipping / rotating / angling or horizontally shifting / sliding, and can also be coupled to each other at the height of the corresponding second pair of opposite edges by flipping / rotating / angling or horizontally shifting / sliding. The panels can also be configured so that they can be coupled to each other according to the so-called downward folding principle. On the first pair of opposite edges, the panels can then be coupled to each other by flipping / rotating / angling movement, and on the second pair of opposite edges, the panels can be coupled to each other by downward movement, wherein the downward movement can be the result of the flipping / rotating / angling movement and thus occurs essentially simultaneously.

[0011] This interlocking connection can produce a stable unit with horizontally and / or vertically interlocked connecting panels. In this context, it should be noted that the expression "horizontal interlocking" is understood to mean an interlocking that acts in the horizontal direction or in the plane of the connecting panels and at right angles to the connecting edges. Vertical interlocking is understood to mean an interlocking that acts in the vertical direction or at right angles to the plane of the connecting panels.

[0012] In some embodiments, the groove depth, measured between the upper plane of the panel and the lowest point of the groove, is less than the vertical height of the convex portion, measured between the lowest point of the convex portion and the upper side of the panel. When the panels are joined, the upper plane of the panel is preferably parallel to the plane in which the panels are joined. The groove depth is therefore a vertical dimension, and the vertical height of the convex portion is therefore a vertical dimension. Without the mating structure according to the present disclosure, the difference between the groove depth and the vertical height of the convex portion may tend to produce residual segments at the corners of the panel after the panel is milled. A mating structure can be provided in the form of a cutout in the lower lip facing the groove, such that the cutout depth, measured between the upper plane and the lowest point of the cutout, is greater than the vertical height of the convex portion. When the panels are joined, the upper plane of the panel is preferably parallel to the plane in which the panels are joined. Therefore, the cutout depth is a vertical dimension. The cutout can form a groove, recess, or indentation, and has a different profile structure than the groove and preferably does not participate in the tongue-and-groove connection. An advantage of the present disclosure is that the mating structure eliminates or prevents the formation of residual segments in the corners of the panel (eg, where the recessed portions of the first pair of opposing edges and the convex portions of the second pair of opposing edges meet).

[0013] The difference between the groove depth and the vertical height of the convex portion may be at most 1 mm, preferably at most 0.5 mm, more preferably at most 0.3 mm, most preferably at most 0.1 mm.

[0014] The total height of the panel may be between 3.20 mm and 10 mm, for example, between 3.50 mm and 6 mm, or between 4.50 mm and 8 mm, or between 6 mm and 7 mm. The depth of the cutout may be 0.1 mm greater than the vertical height of the convex portion, or between 0.1 mm and 0 mm, or more than 0.1 mm. For example, the depth of the cutout may be 0.5 mm, 0.8 mm, 1.2 mm, 1.4 mm, or 1.6 mm greater than the vertical height of the convex portion.

[0015] In another aspect, the depth of the recess, measured between the upper side of the panel and the highest point of the recess, is greater than the vertical height of the recess, measured between the highest point of the recess and the upper plane. When the panels are joined, the upper plane of the panels is preferably parallel to the plane in which the panels are joined. The recess depth is therefore a vertical dimension, and the vertical height of the recess is therefore a vertical dimension. Without the mating structure according to the present disclosure, the difference between the recess depth and the vertical height of the recess may tend to produce residual sections at the corners of the panels after they are milled. A mating structure can be provided, which takes the form of a cutout in the tongue facing the recess. This cutout can have approximately the same width as the recess at the height of the recess, allowing for a smooth transition between the recess and the cutout, and the recess and the cutout together give the appearance of a larger, deeper, or expanded recess. Of course, the cutout can have a smaller width at the height of the recess than the recess. The width is preferably a horizontal dimension. The vertical height of the cutout, measured between the upper side of the panel (e.g., the upper plane) and the highest point of the cutout, is less than the vertical height of the concave portion. When the panels are joined, the upper plane of the panels is preferably parallel to the plane in which the panels are joined. The vertical height of the cutout is therefore the dimension in the vertical direction. An advantage of the present disclosure is that the mating structure eliminates or prevents the formation of residual segments in the corners of the panels (where the tongue of the first pair of opposing edges and the concave portion of the second pair of opposing edges intersect).

[0016] The difference between the recess depth and the vertical height of the concave portion may be at most 1 mm, preferably at most 0.5 mm, more preferably at most 0.3 mm, most preferably at most 0.1 mm.

[0017] The overall height of the panel may be between 3.20 mm and 10 mm, for example between 3.50 mm and 6 mm or between 4.50 mm and 8 mm or between 6 mm and 7 mm.

[0018] The cut depth may be 0.1 mm smaller than the vertical height of the concave portion, or 0.1 mm to 0 mm smaller, or more than 0.1 mm smaller. For example, the cut depth may be 0.5 mm, 0.8 mm, 1.2 mm, 1.4 mm, or 1.6 mm smaller than the vertical height of the convex portion.

[0019] An advantage of the disclosed panels is that the formation of residual segments at one or more corners of the panel can be removed or prevented without the need for a so-called "edge cutter" device or other cutting device. Alternatively, the residual segments can be removed as part of the milling operation to form the panel with the joined portions.

[0020] Preferably, according to the present disclosure, the cutout is positioned so as to avoid participating in the joining of the panels and has a small size to limit any impact on the joining strength of the panels and to reduce the amount of material that must be removed to form the cutout. In certain aspects, the cutout can be provided in the lower lip of the groove at a position distal to the upper lip and the joining plane defined by the upper lip. The cutout in the lower lip and facing the groove is preferably located between the joining plane and the upwardly pointing interlocking portion (if present). The closer the cutout is to the joining plane, the larger the portion that is cut away during milling, and the closer the cutout is to the upwardly pointing interlocking portion, the less impact on the joining strength. If the cutout is located between the joining plane and the upwardly pointing interlocking portion, the cutout can be located in the half closer to the joining plane, in the half closer to the upwardly pointing interlocking portion, or centrally located, as viewed in the horizontal direction, and / or the distance between the cutout and the joining plane can be 0.3 mm, 0.5 mm, 0.7 mm, 1 mm, or greater than 1 mm.

[0021] Note that the male and female coupling portions of the second pair of opposing edges can be tongue and groove, respectively. Other types of coupling portions are not excluded. The coupling portions of the second pair of opposing edges can be coupled, for example, by flipping / rotating / angular movement or horizontal displacement / sliding movement.

[0022] The convex coupling portion and the concave coupling portion of the second pair of opposite edges can be a downwardly pointing upper hook portion and an upwardly pointing lower hook portion. The lower hook portion can include a lip with an upwardly pointing locking element, which defines a concave portion in the form of a recess on its proximal side, while the upper hook portion includes a lip with a downwardly pointing locking element, which forms a convex portion. These coupling portions can be connected to each other by moving downward. Preferably, the coupling portions of the first pair of opposite edges can then be connected to each other, preferably by flipping / rotating / angling, so that in the same flipping / rotating / angling movement, the coupling portions of the second pair of opposite edges also connect to each other.

[0023] The panels can preferably be configured as laminate panels, elastic panels, etc. Thus, the panels can be provided as floor, wall or ceiling panels. Other types of panels are not excluded.

[0024] The panel is preferably a decorative panel. A decorative panel is provided with a decoration on its upper side which is visible in the mounted position. The decoration may be of any type, such as wood or stone decoration.

[0025] The panel's base can be made of wood. For example, the base can consist of several wooden planks connected to one another. This is typically the case with engineered wood. However, the base can also be formed as a single component made of wood (e.g., solid wood).

[0026] The substrate of the panel can include wood particles and an adhesive for bonding the wood particles to each other. This substrate is a wood-based substrate. The wood particles can be wood fibers and / or wood chips. The adhesive can be a glue or resin, such as melamine urea-formaldehyde resin, urea-formaldehyde resin or isocyanate resin. Bio-based resins (such as resins containing sugar, lignin, amines and / or flour) are also possible. The substrate includes, for example, wood fiberboard, such as medium-density fiberboard (MDF) or high-density fiberboard (HDF), or cardboard. One or more resin-impregnated papers can be laminated on this wood-based substrate. Other layers are also possible. A facing layer or a log layer can be attached to the wood-based substrate.

[0027] The substrate of the panel may include a thermoplastic material. The thermoplastic material includes a thermoplastic plastic. The thermoplastic plastic may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), or polyethylene terephthalate (PET). The thermoplastic material may include polyvinyl chloride or another thermoplastic material, with or without a plasticizer. The thermoplastic material may be foamed or unfoamed. The thermoplastic material may include a closed-cell foam or an open-cell foam. The thermoplastic material may include a filler. The filler may be an organic filler, such as wood particles. The filler may be an inorganic and / or mineral filler. The filler may be a mineral filler, such as calcium carbonate, chalk, or limestone. The filler may be talc.

[0028] The panel substrate may include a thermosetting material. The thermosetting material may include a thermosetting plastic. The thermosetting plastic may be polyurethane (PU). The thermosetting material may include a filler. The filler may be an organic filler, such as wood particles. The filler may be an inorganic filler. The filler may be a mineral filler, such as calcium carbonate, for example, chalk or limestone. The filler may be talc.

[0029] The substrate of the panels may comprise any other desired material, such as cement fiber panels or magnesium panels.

[0030] The panel can be formed as a single component. For example, the panel can be formed as a single component made of wood. For example, this is the case with solid parquet. The panel can be a multi-layer panel, such as a laminate panel comprising a wood-based substrate and several resin-impregnated papers, or a resilient panel comprising several layers containing thermoplastic material.

[0031] The present disclosure also relates to a method for manufacturing a panel having a mating structure in the form of a cutout. The method comprises at least the following steps:

[0032] advancing a panel having an upper side defining an upper plane relative to a first milling device having at least two milling tools;

[0033] processing a first pair of opposing edges of the panel using at least two milling tools of a first milling device to form a coupling portion in the form of a tongue at one of the first pair of opposing edges and a groove at the other of the first pair of opposing edges, the groove being defined by an upper lip and a lower lip, wherein the lower lip extends distally beyond the upper lip, and the tongue defines a recess opposite an upper side of the panel and configured to receive a portion of the lower lip;

[0034] in:

[0035] the lower lip comprises a cutout facing the groove such that the depth of the cutout measured between the upper plane and the lowest point of the cutout is greater than the vertical height of the convex portion measured between the lowest point of the convex portion and the upper side of the panel; and / or

[0036] The tongue further comprises a cutout facing the recess such that a vertical height of the cutout measured between an upper side of the panel and a highest point of the cutout is smaller than a vertical height of the concave portion measured between a highest point of the concave portion and the upper plane.

[0037] Forming the coupling portion using a cutting or milling operation effectively produces precise results.The cutting or milling tool is preferably a rotary cutting or milling tool.

[0038] Thus, the tongue and groove can be formed, for example, using one or several cutting or milling tools, for example some or all of the cutting or milling tools can be fixed cutting or milling tools. A fixed cutting or milling tool is a cutting or milling tool that has a base part and / or an axis that has a fixed position during milling and therefore does not move towards or away from the panel during milling. In this case, the cutting or milling tool can be rotated or perform local cutting movements. After one or more processes using one or several cutting or milling tools, the cut can be present along the entire or almost the entire corresponding edge. The cutting or milling tool does not have to be fixed during milling. Between milling movements, the base part and / or the axis can be displaced, and this will be used to mill other contour structures.

[0039] Preferably, the method comprises the further steps of:

[0040] advancing the panel relative to a second milling device having at least two milling tools; and

[0041] A second pair of opposing edges of the panel is processed using at least two milling tools of a second milling device to form coupling portions in the form of a male coupling portion at one of the second pair of opposing edges and a female coupling portion at the other of the second pair of opposing edges.

[0042] The tongue on one of the first pair of opposing edges may be formed using cutting or milling tools, some or all of which may be fixed cutting or milling tools. This may effectively ensure that these elements are present along the entire or substantially the entire edge of the first pair of opposing edges.

[0043] The groove on the other edge of the first pair of opposite edges can be formed using one or more cutting or milling tools (e.g., fixed cutting or milling tools). This can effectively ensure that the element is present along the entire or nearly the entire other edge of the first pair of opposite edges.

[0044] The male and female coupling portions on one and / or the other of the second pair of opposing edges can be formed using one or more cutting or milling tools (e.g., fixed cutting or milling tools). This effectively ensures that the element is present along the entire or nearly the entire edge of the second pair of opposing edges.

[0045] In another aspect, the present disclosure relates to manufacturing a panel wherein residual segments in a corner of the panel are prevented from forming or are removed by moving a milling tool. The method comprises at least the following steps:

[0046] advancing a panel having an upper side defining an upper plane relative to a first milling device having at least two milling tools;

[0047] processing a first pair of opposing edges of the panel using at least two milling tools of a first milling device to form a coupling portion in the form of a tongue at one of the first pair of opposing edges and a groove at the other of the first pair of opposing edges, the groove being delimited by an upper lip and a lower lip;

[0048] advancing the panel relative to a second milling device having at least two milling tools;

[0049] processing a second pair of opposing edges of the panel using at least two milling tools of a second milling device to form coupling portions in the form of a male coupling portion at one of the second pair of opposing edges and a female coupling portion at the other of the second pair of opposing edges;

[0050] Wherein, during processing of a corner area defined by an overlapping portion of one edge of a first pair of opposite edges and one edge of a second pair of opposite edges, the at least two milling tools of the first milling device and / or the milling tools of the at least two milling tools of the second milling device are moved in a vertical direction relative to the upper side of the panel so as to remove or prevent the formation of the corner segment.

[0051] Preferably, during milling of the panel corner region, at least one of the cutting or milling tools is moved vertically toward the panel relative to the upper side of the panel. This means that a portion of the cutting tool and / or the axis of rotation of the milling tool can be moved vertically. This allows the cutting or milling tool to locally make a deeper cut at the height of the panel corner, which facilitates the removal of excess material at the panel corner without affecting the profile of the joint.

[0052] A mobile cutting or milling tool may be used on the first pair of opposing edges and / or the second pair of opposing edges. Preferably, one or more mobile cutting or milling tools are used on edges where residual segments may exist or must be removed. According to this aspect of the present disclosure, a combination of fixed and mobile cutting or milling tools may be used to manufacture the panel.

[0053] In another aspect, the present disclosure relates to a method for designing a panel in which residual segments in the corners of the panel are prevented from forming or are removed. The panel may have an upper side defining an upper plane and include a first pair of opposing edges and a second pair of opposing edges. The first pair of opposing edges may be provided with a coupling portion in the form of a tongue at one edge of the first pair of opposing edges and a groove at the other edge of the first pair of opposing edges, the groove being defined by an upper lip and a lower lip, wherein the lower lip extends distally beyond the upper lip. The second pair of opposing edges may be provided with a coupling portion in the form of a convex coupling portion at one edge of the second pair of opposing edges and a concave coupling portion at the other edge of the second pair of opposing edges. The method comprises at least the following steps:

[0054] Determine the groove depth measured between the upper plane and the lowest point of the groove;

[0055] determining the vertical height of the convex portion measured between the lowest point of the convex portion and the upper side of the panel;

[0056] determining the depth of the recess as measured between the upper side of the panel and the highest point of the recess;

[0057] determining a vertical height of the concave portion measured between the highest point of the concave portion and the upper plane;

[0058] When the groove depth is less than the vertical height of the convex portion, adding an undercut to the lower lip, the undercut facing the groove and having a depth measured between the upper plane and the lowest point of the undercut that is greater than the vertical height of the convex portion; and

[0059] When the recess depth is greater than the vertical height of the concave part, an upper cutout is added to the tongue, the upper cutout facing the recess and having a vertical height measured between the upper side of the panel and the highest point of the upper cutout, which is less than the vertical height of the concave part.

[0060] The method of designing the panel may be automatically performed during the method of forming the panel, such as using a computer controlled design program.Thus, according to embodiments of the present disclosure, an improved panel may be achieved.

[0061] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to serve as an indicator of the scope of the claimed subject matter.

[0062] Additional features and advantages of the present disclosure will be summarized in the following description, and in part will be clear from the description or can be learned through practice of the present disclosure. The features and advantages of the present disclosure can be realized and obtained using the means and combinations particularly pointed out in the appended claims. These and other features of the present disclosure will become more apparent from the following description and the appended claims, or can be learned through practice of the disclosure as set forth below. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] In order to illustrate the features of the present invention in more detail, some preferred embodiments are described below by way of example with reference to the accompanying drawings, but not by way of limitation.

[0064] Figure 1 is a schematic diagram illustrating a method according to an aspect of the present disclosure.

[0065] Figure 2 is a perspective view of the panel when the profile structure is not fitted and corner segments are present.

[0066] Figure 3A It is along Figure 2 The cross-sectional view taken along the relevant line III-III in FIG.

[0067] Figure 3B is a cross-sectional view of a groove coupling portion adapted according to various aspects of the present disclosure, wherein the contour structure of the adjacent convex coupling portion is overlaid with a dashed line over the groove coupling portion.

[0068] Figure 4 It is along Figure 2 A cross-sectional view taken along the relevant line III-III in which the milling operation provides the mating structure.

[0069] Figure 5A It is aimed at Figure 2 The relative corners of the panel are similar to Figure 3ACross-sectional view of .

[0070] Figure 5B is a cross-sectional view of a tongue coupling portion adapted according to aspects of the present disclosure, with the contour structure of an adjacent female coupling portion overlaying the tongue coupling portion in dashed lines.

[0071] Figure 6 is similar to Figure 4 A cross-sectional view of the milling operation Figure 2 Opposing corners of the panels provide mating structure.

[0072] Figure 7 is a perspective view of the panel when the profile structure has been adapted and no corner segments are present.

[0073] Figure 8 is a sectional view showing a coupled portion of a first pair of opposing edges in a coupled state.

[0074] Figure 9 It is along Figure 2 The cross-sectional view taken along the relevant line III-III in FIG shows various possible matching structures.

[0075] Figure 10 It is based on a variant similar to Figure 4 A cross-sectional view of a milling operation including vertical movement to provide a mating structure.

[0076] Figure 11 is based on Figure 10 A variant similar to Figure 7 Stereoscopic image.

[0077] Figure 12 is a perspective view of the panel variant when the profile structure does not fit and corner sections are present.

[0078] Figure 13 is similar to Figure 4 A cross-sectional view showing the Figure 12 The fitting structure is provided by the milling operation of the panel.

[0079] Figure 14 yes Figure 12 A perspective view of a panel in which the profile structure has been adapted and no corner segments are present. DETAILED DESCRIPTION

[0080] Overview

[0081] The various embodiments of the present disclosure may be better understood from the following description and accompanying drawings, in which like reference numerals refer to like elements.

[0082] While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are shown in the accompanying drawings and described below. It should be understood that the present disclosure is not intended to be limited to the particular embodiments disclosed, but on the contrary, the present disclosure is intended to cover all modifications, alternative constructions, combinations and equivalents falling within the spirit and scope of the present disclosure.

[0083] It should be understood that unless a term is expressly defined in this application to have a described meaning, no limitation, either express or indirect, is intended to limit the meaning of such term beyond its ordinary or common meaning.

[0084] Any element in a claim that does not explicitly recite "means" for performing a specified function or "step" for performing a specified function should not be construed as a "means" or "step" clause as provided in 35 USC §112.

[0085] Multiple implementations

[0086] Figure 1 A schematic diagram illustrates how a panel 10 can be obtained using the method according to the first aspect of the present disclosure. In the illustrated example, two processing machines, more particularly continuous milling machines 50, 51, are used to provide the panel 10 with coupling portions at a first pair of opposite edges 14, 15 and at a second pair of opposite edges 56, 57. Here, so-called "continuous milling" is applied. Initially, the panel 10 is moved so that the first pair of opposite edges 14, 15 are on mechanical cutting tools 52a, 52b. The second pair of opposite edges 56, 57 is then subjected to a similar process.

[0087] Note that although Figure 1 In the depicted embodiment, a rectangular panel 10 is shown, but the panel 10 may be rectangular or square. The panel 10 is preferably displaced using two sequential vertical movements V1 and V2, whereby during the first movement V1, the mechanical cutting tools 52a, 52b are used to provide the profile structure at the first pair of opposite edges 14, 15 (in the case shown, the longitudinal edges), while during the second movement V2, the mechanical cutting tools 52a, 52b are used to provide the profile structure at the second pair of opposite edges 56, 57 (in the case shown, the transverse edges or short edges). During this processing, the panel 10 is preferably oriented so that the upper side of the panel 10 points downward, so that in the example shown, the lower side 11 of the panel 10 is shown.

[0088] The illustrated panel 10 may comprise any suitable material used in panels (such as forming a laminate panel, an elastic panel, etc.). Other types of panels are not excluded. Thus, the panel 10 may comprise a base where the joining portions of the two edges meet at a corner, as will be clear to those skilled in the art from this disclosure.

[0089] The panel is preferably a decorative panel. The decorative panel is provided with a decoration on its upper side which is visible in the mounted position. The decoration may be any decoration, such as wood or stone decoration.

[0090] The panel's base can be made of wood. For example, the base can consist of several wooden planks connected to one another. This is typically the case with engineered wood. However, the base can also be formed as a single component made of wood (e.g., solid wood).

[0091] The substrate of the panel may include wood particles and an adhesive for bonding the wood particles to each other. The wood particles may be wood fibers and / or wood chips. The adhesive may be a glue or resin, such as melamine, formaldehyde, or an isocyanate resin. The substrate may include, for example, a wood fiberboard, such as medium-density fiberboard (MDF) or high-density fiberboard (HDF), or cardboard.

[0092] The substrate of the panel may include a thermoplastic material. The thermoplastic material includes a thermoplastic plastic. The thermoplastic plastic may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), or polyethylene terephthalate (PET). The thermoplastic material may include polyvinyl chloride with or without a plasticizer. The thermoplastic material may be foamed or unfoamed. The thermoplastic material may include a closed-cell foam or an open-cell foam. The thermoplastic material may include a filler. The filler may be an organic filler, such as wood particles. The filler may be inorganic. The filler may be a mineral filler, such as calcium carbonate, for example, chalk or limestone. The filler may be talc.

[0093] The panel substrate may include a thermosetting material. The thermosetting material may include a thermosetting plastic. The thermosetting plastic may be polyurethane (PU). The thermosetting material may include a filler. The filler may be organic, such as wood particles. The filler may be inorganic. The filler may be a mineral filler, such as calcium carbonate, for example, chalk or limestone. The filler may be talc.

[0094] The substrate of the panels may comprise any other desired material, such as cement fiber panels or magnesium panels.

[0095] The panel can be formed as a single component. The panel can, for example, be formed as a single component made of wood. This is the case, for example, with solid wood parquet. The panel can be a multi-layer panel.

[0096] According to one aspect of the present disclosure, the contours of the edges 14, 15, 56, 57 are formed using a milling process having a plurality of sequential milling cycles or passes using mechanical cutting tools 52a, 52b or milling cutters positioned at different angles relative to the associated panel 10. The first pair of opposing edges 14, 15 may be provided with tongues 16 and grooves 17 as corresponding coupling portions using the milling tool or cutter using 2 to 8 milling cycles, for example four or six milling cycles.

[0097] A panel 10 having a joint portion according to the present disclosure can be formed by advancing the panel 10 relative to a first milling device 50 having at least two milling tools 52a, 52b. The milling tools 52a, 52b can be positioned at two opposing edges of the panel 10 to simultaneously process two opposing edges 14, 15 of the panel 10. According to some embodiments, the milling tools can be configured as rotating milling tools and can be fixed cutting tools during milling, for example having an axis of rotation that has a fixed position during use, or the milling tools can be movable in a horizontal direction parallel to the plane of the panel. As the panel 10 is advanced through the first milling device 50, the first pair of opposing edges 14, 15 are processed to form the joint portion. As the panel passes through the milling tools in sequential milling cycles, each milling tool can form a face or side with a corresponding tongue or groove. Such cuts can be made by a single milling tool. However, preferably, such cuts 22, 35 are made by a milling tool that also forms another face or side with a corresponding tongue or groove. The parts with the cutouts 22 , 35 can also be produced using different milling tools.

[0098] Figure 2 The perspective view of the underside of the panel 10 in FIG. 1 shows a contoured edge region formed by the edges 14, 15, 56, 57 of the panel 10 during the milling operation, the contoured edge region comprising coupling portions, more particularly in the form of a tongue 16 and groove 17 at a first pair of opposing edges 14, 15, and in the form of a female coupling portion 28 and a male coupling portion 29 at a second pair of opposing edges 56, 57. Figure 3A As shown in FIG, the groove 17 is delimited by a lower lip 18 and an upper lip 19, wherein in the example shown, the lower lip 18 extends beyond the upper lip 19 and includes an upwardly directed interlocking portion forming the distalmost point of the lower lip 18. Figure 8 In the further discussed coupled state of at least two of the above-mentioned panels 10, the illustrated tongue 16 and groove 17 produce a horizontal as well as a vertical interlocking of the respective panels 10. Of course, other coupling portions are possible according to different variations of the present disclosure, and the features of the specific embodiments are equally applicable to such different types of coupling portions. Figure 2The panels 10 shown in FIG. 5 are configured such that such panels 10 can be coupled to one another according to the so-called flip-down principle.

[0099] The panel 10 can be advanced against a second milling device 51 having at least two milling tools 52a, 52b, such as those positioned at opposite edges of the panel to simultaneously process both opposing edges 56, 57. As the panel 10 advances through the second milling device 51, the second pair of opposing edges 56, 57 are processed to form coupling portions, which are provided in the form of a male coupling portion 29 at one edge 56 of the second pair of opposing edges and a female coupling portion 28 at the other edge 57 of the second pair of opposing edges 56, 57. The male coupling portion 29 and the female coupling portion 28 of the second pair of opposing edges 56, 57 are downwardly directed upper hook portions and upwardly directed lower hook portions. The lower hook portion includes a lip having an upwardly directed locking element, which defines a concave portion in the form of a recess on its proximal side, while the upper hook portion includes a lip having a downwardly directed locking element, which forms a male portion. As previously mentioned, other coupling portions are possible according to different variations of the present disclosure, and the features of the specific embodiments are equally applicable to such different types of coupling portions.

[0100] As from Figure 2 As will become readily apparent, problems may arise at the corners 60 of the panel 10 for coupling portions of a particular size or thickness, resulting in residual segments 30, 31 remaining attached to the panel 10. In the example shown, the residual segment 30 is located at the corner where the groove 17 of the first pair of opposing edges 14, 15 meets the male coupling portion 29 of the second pair of opposing edges 56, 57, while the residual segment 31 is located at the corner where the tongue 16 of the first pair of opposing edges 14, 15 meets the female coupling portion 28 of the second pair of opposing edges 56, 57. This result may occur due to the overlapping thicknesses of the corresponding contoured edges, such that after a standard milling operation, material portions A, B remain to connect the residual segments 30, 31 to the panel 10.

[0101] Figure 3A Provided Figure 2FIG3 is a cross-section III-III of FIG3 , which is reoriented to show the upper side 13 and the underside 11 of the panel 10. The depicted panel 10 includes a groove 17 bounded by a lower lip 18 and an upper lip 19 such that a groove depth 20 measured between an upper plane 48 of the panel 10 and a lowest point 21 of the groove 17 is less than a vertical height 32 of the convex portion 29 measured between a lowest point 33 of the convex portion 29 and the upper side 13 of the panel 10. The difference between the groove depth 20 and the vertical height 32 of the convex portion 29 creates a portion A of material that may remain after the milling process, such that a residual segment 30 remains at the corner of the panel 10.

[0102] In alternative embodiments, the difference between the groove depth 20 and the vertical height 32 of the convex portion 29 may be no greater than 1 mm, preferably no greater than 0.5 mm, more preferably no greater than 0.3 mm, and most preferably no greater than 0.1 mm. It should be noted that this limited amount of material is still problematic due to its tendency to break away from the panel 10 at unpredictable moments and may leave dangerous sharp edges or otherwise damage the contoured edge if pulled or caught.

[0103] As previously discussed, it is preferred that the residual section 30 be removed during the milling process without the need for additional components or intervention. In an embodiment of the presently disclosed method, at least two milling tools 52a, 52b of a first milling device 50 may be used to process the first pair of opposing edges 14, 15 to form a coupling portion in the form of a tongue 16 at one edge 14 of the first pair of opposing edges and a groove 17 at the other edge 15 of the first pair of opposing edges, the groove 17 being defined by an upper lip 19 and a lower lip 18. During the processing of the first pair of opposing edges 14, 15, one or more of the milling tools may be adapted to form one or more of the following:

[0104] a cutout in the lower lip and facing the groove, such that the depth of the cutout measured between the upper plane and the lowest point of the cutout is greater than the vertical height of the convex portion measured between the lowest point of the convex portion and the upper side of the panel; and

[0105] The cutout in the tongue and facing the recess of the tongue is such that the vertical height of the cutout measured between the upper side of the panel and the highest point of the cutout is smaller than the vertical height of the concave part measured between its highest point and the upper plane.

[0106] Figure 3B 17, wherein the profile of the male coupling portion 29 is shown in dashed lines overlying the groove 17. According to one aspect of the present disclosure, the lower lip 18 may be adapted to include a cutout 22 facing the groove 17, such as Figure 3BThus, the cut depth 23 measured between the upper plane 48 and the lowest point 24 of the cut 22 is greater than the vertical height 32 of the convex portion 29 measured between the lowest point 33 of the convex portion 29 and the upper side 13 of the panel 10, so that the material portion A is removed by the cut 22 and the formation of the residual segment 30 is prevented or the residual segment is removed (according to Figure 7 ).

[0107] In alternative embodiments, the cut depth 23 can be selected to ensure that the residual section 30 is removed while minimizing any loss of material strength in the lower lip 18 that might be caused by an excessively deep cut 22. For example, the cut depth 23 can be 0.1 mm greater than the vertical height 32 of the convex portion 29, or from 0.1 mm to 0 mm, or more than 0.1 mm. Advantageously, the cut 22 does not participate in the coupling of the tongue 16 and the groove 17, making it possible to prevent the formation of the residual section 30 or remove the residual section without affecting the coupling performance of the panel 10.

[0108] The cutouts 22 can be made by modifying existing milling operations or tools or by adding additional milling operations or tools. Figure 4 As shown in , an additional milling tool 80 can be used to form the cutout 22, one or more milling tools can form the cutout during one of the multiple milling cycles, or the cutout 22 can be formed in a different milling cycle. Preferably, the cutout 22 is formed in an existing milling cycle or at least in an existing milling device, so that the panel can be manufactured efficiently without requiring additional space and expense.

[0109] Figure 5A Provided with Figure 3A A similar view, but for the opposite corner of the panel 10. The depicted panel 10 includes a tongue 16 defining a recess 25 configured to receive a portion of the lower lip 18 of the first pair of opposing edges. Figure 5A 1. The lower lip 18 includes an upwardly directed interlocking portion, wherein the recess 25 is configured to receive the upwardly directed interlocking portion. The recess 25 has a recess depth 26 measured between the upper side 13 of the panel 10 and the highest point 27 of the recess 25, which is greater than the vertical height 34 of the recess 28 measured between the highest point 37 of the recess 28 and the upper plane 48 of the panel 10. The difference between the recess depth 26 and the vertical height 34 of the recess 28 creates a portion of material B that may remain after the milling process, such that a residual segment 31 remains at the corner of the panel 10.

[0110] In alternative embodiments, the difference between the recess depth 26 and the vertical height 34 of the concave portion 28 may be no greater than 1 mm, preferably no greater than 0.5 mm, more preferably no greater than 0.3 mm, and most preferably no greater than 0.1 mm. As previously mentioned, this limited amount of material is still problematic due to its tendency to break away from the panel 10 at unpredictable moments and may leave dangerous sharp edges or otherwise damage the contoured edge if pulled or caught.

[0111] Preferably, the residual section 31 is removed during the milling process without the need for additional components or intervention. Figure 5B A cross section of the tongue 16 is shown, wherein the outline of the female coupling portion 28 is shown in dashed lines covering the tongue 16. According to an aspect of the present disclosure, the tongue 16 may be adapted to comprise a cutout 35 facing the recess 25, such as Figure 5B Thus, the vertical height 36 of the cutout 35 measured between the upper side 13 of the panel 10 and the highest point 46 of the cutout 35 is less than the vertical height 34 of the concave portion 28 measured between the highest point 37 of the concave portion 28 and the upper plane 48 of the panel 10, so that the material portion B is removed by the cutout 35 and the formation of the residual segment 31 (according to Figure 7 ).

[0112] In alternative embodiments, the vertical height 36 of the cutout 35 can be selected to ensure that the residual section 31 is removed while minimizing any loss of material strength in the tongue 16 that might result from an excessively deep cutout 35. For example, the cutout depth 35 can be 0.1 mm less than the vertical height 34 of the recessed portion 28, or from 0.1 mm to 0 mm, or more than 0.1 mm less. Advantageously, the cutout 35 does not participate in the connection between the tongue 16 and the groove 17, allowing the residual section 31 to be removed or prevented from forming without affecting the connection properties of the panel 10. In certain embodiments, the cutout 35 can extend the entire recess 25 or be provided as a more limited, localized cutout.

[0113] The cutouts 35 can be made by modifying an existing milling operation or milling tool or by adding an additional milling operation or milling tool. Figure 6 As shown in , an additional milling tool 82 can be used to form the cutout 35, one or more milling tools can form the cutout during one of the milling cycles, or the cutout 35 can be formed in a different milling cycle. Preferably, the cutout 35 is formed in an existing milling cycle or at least in an existing milling device, so that the panel can be manufactured efficiently without the need for trimming cutters or other devices, and without the need for additional space and expense.

[0114] from Figure 7It will be apparent that, according to an aspect of the present disclosure, the formation of residual segments 30 and 31 may be prevented or removed in other ways. Of course, it is possible that certain dimensions for the joining portion of the panels result in a residual segment at only one corner, so that an aspect of the disclosed embodiment may involve providing a cutout at only one of the first opposing edges 14, 15 or at both first opposing edges 14, 15.

[0115] Figure 8 Two panels 10 manufactured or adapted according to the presently disclosed method are shown in a coupled state of a first pair of opposing edges. Here, the tongue 16 and the groove 17 are provided as cooperating coupling parts. As shown in the depicted embodiment, the groove 17 can be defined by a lower lip 18 and an upper lip 19 including locking portions 38, 39 and a contact surface 40. The tongue 16 can include corresponding contact surfaces 41 and locking portions 42, 43, which are configured to cooperate with the locking portions 38, 39 and the contact surface 40 in the coupled state of the panels 10. In this case, the tongue 16 and the groove 17 can be coupled by relative movement of the panels 10 (e.g., rotational movement or translational movement), and a snap fit, a snap fit, or the like may or may not occur.

[0116] As in Figure 8 In the depicted embodiment, one or both of the tongue 16 and groove 17 may include a cutout 22, 35. According to one aspect of the present disclosure, the cutout 22, 35 may not participate in the joining of the panels 10. For example, although the cutout 22 is shown as being provided in the lower lip 18, the cutout 22 does not abut or contact the tongue 16. In a similar manner, Figure 8 The cutout 35 is shown as an extension of the recess 25, wherein, in the coupled state, the locking portion 38 of the lower lip 18 does not enter the cutout 35. It should be noted that other forms of locking portions or tongue and groove profiles are not excluded.

[0117] from Figure 8 As will be apparent from the foregoing, the location, size, and shape of the cutouts can vary according to various aspects of the present disclosure while still achieving the advantages of preventing the formation of residual segments of material or removing residual segments. Thus, the cutouts 35 can be more localized cutouts, such as not extending across the entire width of the recess 25. Similarly, the cutouts 22 can be provided in the lower lip 18 at locations other than those shown in the depicted embodiment, with corresponding differences in the cutout depths.

[0118] In a preferred embodiment, the cutout 22 in the lower lip 18 is located distally of the closure plane 44 defined by the contact surfaces 40 , 41 . Figure 9 As a number of alternatives, cutouts 22a, 22b, 22c are shown. Figure 9As can be seen, as the distance between the cutouts 22a, 22b, 22c and the closure plane 44 decreases, the amount of material that must be removed to form the respective cutouts 22a, 22b, 22c increases to ensure that the cutout depth 23 measured between the upper plane 48 of the panel 10 and the lowest point 24 of the cutouts 22a, 22b, 22c is greater than the vertical height 32 of the convex portion 29 measured between the lowest point 33 of the convex portion 29 and the upper side 13 of the panel 10. As more material is removed to form the cutouts 22a, 22b, 22c, more coupling strength will be lost in the respective panel 10.

[0119] In a similar manner, as the distance between the cutouts 22a, 22b, 22c and the closure plane 44 increases, the amount of material that must be removed to form the respective cutouts 22a, 22b, 22c decreases. Thus, the further the cutouts 22a, 22b, 22c are from the closure plane 44, the less material must be removed to form the cutouts 22a, 22b, 22c, and the less joint strength is lost.

[0120] Preferably, the cutouts according to the disclosed embodiments can be very small and have any shape that can be achieved by milling. More particularly, it can be preferred that the cutouts have the necessary depth but have a minimum width measured in the distal direction of the panel.

[0121] Figures 10 and 11 A variation of the present disclosure is shown in which a direct milling operation can remove excess material portion C without changing the profile structure of the coupling portion. According to this aspect of the present disclosure, a milling tool 53 can be provided that can be moved vertically during the milling operation. For example, the milling tool 53 can be configured to mill the male coupling portion 29 of the second pair of opposing edges 56, 57. During the milling operation of the edge 56, the milling tool 53 can be located at a first position 54 or height, and when reaching the corner of the panel 10, the milling tool can be moved in a vertical direction toward the upper side 13 of the panel 10 to a second position 59 or height. A corner can be defined as the overlapping area of the two edges 15, 56 of the panel 10.

[0122] according to Figures 10 and 11 In this aspect, since the milling tool 53 removes or cuts the corners, the formation of the residual section 30 can be removed or prevented. In a variant embodiment, the panel 10 can be moved in the vertical direction, such as by configuring an air mattress, belts, shoes, supports or other components of a transport system for the milling operation, and this is used to remove or cut the corners. For the residual section 31, it is possible to perform and / or repeat the operation according to the embodiment of the present invention on the edge 57 during the milling of the concave coupling portion 28. Figures 10 and 11 operation.

[0123] In a related aspect, the milling tool can be moved vertically during the milling operation of the groove 17 of the first pair of opposing edges 14, 15. In this example, during the milling operation of edge 15, the milling tool can be located at a first position 54, or height, and upon reaching the corner of the panel 10, the milling tool can be moved vertically to a second position 59, or height, toward the upper side 13 of the panel 10. In this manner, as the milling tool fully or partially removes or cuts the corner, the formation of the residual segment 30 can be removed or prevented. In some aspects, the movement of the milling tool can remove sufficient material so that the milling tool 53 can complete the removal of the residual segment 30 during the milling of the male coupling portion 29 without requiring vertical movement. In a variation, the movement of the milling tool can substantially remove the residual segment 30 before milling the male coupling portion 29. This operation can be performed and / or repeated on the edge 14 during the milling of the tongue 16 using the milling tool to remove the residual segment 31.

[0124] As from Figures 10 and 11 As is clear from the disclosed aspects, the removal or prevention of the formation of the residual segments 30, 31 does not require the use of a separate so-called trimming knife device. Instead, as discussed above, a rotary milling tool can be provided that is configured to "jump" or move in the vertical direction so that the milling tool cuts deeper at the corners of the panel so that the residual segments 30, 31 may no longer exist. Advantageously, the movement of the milling tool achieves the removal or prevention of the formation of the residual segments 30, 31 at the corners of the panel 10 without requiring any adaptation of the coupling part itself. A similar result can be achieved by a transport system that is suitable for moving the panel 10 in the vertical direction during milling of the corners.

[0125] Figures 12 to 14 5. The present invention illustrates how various aspects of the present disclosure may be implemented with respect to a panel 10 in which a second pair of opposing edges 56, 57 is provided with different coupling portions. In the depicted example, both the first and second pairs of opposing edges 56, 57 include coupling portions in the form of tongues 16, 56 and grooves 17, 57. It should be noted that the relative dimensions of the tongue 16, 56 and groove 17, 57 coupling portions may be configured to remove or prevent the formation of a residual segment 55 and to potentially retain a sharp segment 58 at a corner. As with the other residual segments discussed herein, the sharp segment 58 may present problems with further processing of the panel 10 due to its tendency to break away from the panel 10 (such as during a painting or coating operation) or otherwise present a sharp edge that could injure an installer or damage a contoured edge if pulled or caught.

[0126] Thus, one or both of the first pair of opposing edges 14, 15 may be adapted to include a cutout 22 in accordance with aspects of the present disclosure discussed previously. Figure 13As shown in FIG, a cutout 22 may be formed in the lower lip 18 of the groove 17 by a milling operation. Of course, such a cutout 22 may be provided in one or both of the tongue 16 and the groove 17 of the first pair of opposing edges, as described with respect to FIG. Figure 8 discussed.

[0127] As from Figure 12 and Figure 14 As is clear from a comparison of the cuts 22, the cutouts 22 enable the sharp segments 58 to be removed from the panel 10 so that there are no sharp segments that could become detached from the panel 10 during further processing or cause damage to the panel or the installer. Figures 10 and 11 The various aspects of the disclosure discussed may also be applicable to Figure 12 The panel 10 is provided with a plurality of strips of material to allow the sharp section 58 to be removed without requiring a separate trimming knife device or an adaptable profile structure of the coupling portion.

[0128] In another aspect, the present disclosure relates to a method for designing a panel 10 in which residual segments 30, 31 are prevented from forming or are removed in corners 60 of the panel 10. The panel 10 can have an upper side 13 defining an upper plane 48, the panel 10 including a first pair of opposing edges 14, 15 and a second pair of opposing edges 56, 57, as shown in the depicted embodiment.

[0129] The first pair of opposing edges 14, 15 may be provided with a coupling portion in the form of a tongue 16 at one edge 14 of the first pair of opposing edges and a groove 17 at the other edge 15 of the first pair of opposing edges, the groove 17 being bounded by an upper lip 19 and a lower lip 18, wherein the lower lip 18 extends distally beyond the upper lip 19. The second pair of opposing edges 56, 57 may be provided with a coupling portion in the form of a male coupling portion 29 at one edge 56 of the second pair of opposing edges 56, 57 and a female coupling portion 28 at the other edge 57 of the second pair of opposing edges 56, 57.

[0130] The panel 10 can be designed in the following ways:

[0131] Determine the groove depth 20 measured between the upper plane 48 and the lowest point 21 of the groove 17;

[0132] determining a vertical height 32 of the convex portion 29 measured between the lowest point 33 of the convex portion 29 and the upper side 13 of the panel 10;

[0133] determining the depth 26 of the recess as measured between the upper side 13 of the panel 10 and the highest point 27 of the recess 25;

[0134] determining the vertical height 34 of the concave portion 28 as measured between the highest point 37 of the concave portion 28 and the upper plane 48;

[0135] When the groove depth 20 is less than the vertical height 32 of the convex portion 29 , adding a lower cutout 22 to the lower lip 18 , the lower cutout 22 facing the groove 17 and having a depth 23 measured between the upper plane 48 and the lowest point 24 of the lower cutout 22 , which is greater than the vertical height 32 of the convex portion 29 ; and

[0136] When the recess depth 26 is greater than the vertical height 34 of the concave portion 28, an upper cutout 35 is added to the tongue 16, the upper cutout 35 facing the recess 25 and having a vertical height 36 measured between the upper side 13 of the panel 10 and the highest point 46 of the upper cutout 35, which is less than the vertical height 34 of the concave portion 28.

[0137] The method for designing panels can be automated using a computer-controlled design program. Furthermore, the method can be applied to new or existing panel designs, allowing the manufacturing method or associated milling system to be adapted to remove or prevent the formation of residual segments at corners without the need for additional devices or processes. Instead, residual segments at corners can be removed or prevented during panel milling. Thus, according to embodiments of the present disclosure, improved panels can be achieved.

[0138] The present invention is in no way limited to the embodiments described above, but rather different variations of such panels can be produced without departing from the scope of the present invention. It should be understood that all further aspects of the present invention relating to the method can be combined in an unrestricted manner, with advantageous synergistic effects possibly occurring or not. Furthermore, it should be noted that the present invention also relates to panels produced according to any of the above methods or by a combination of the above methods.

Claims

1. A panel (10) for forming a covering, said panel having an upper side (13) defining an upper plane (48), in, The panel (10) includes a first pair of opposing edges (14, 15) and a second pair of opposing edges (56, 57); the first pair of opposite edges (14, 15) being provided with a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18), wherein the lower lip (18) extends distally beyond the upper lip (19); the second pair of opposing edges (56, 57) being provided with coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposing edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposing edges (56, 57); wherein the lower lip (18) comprises a cutout (22) facing the groove (17) such that a depth (23) of the cutout measured between the upper plane (48) and the lowest point (24) of the cutout (22) is greater than a vertical height (32) of the convex portion (29) measured between the lowest point (33) of the convex portion (29) and the upper side (13) of the panel (10).

2. The panel (10) according to claim 1, wherein The groove depth (20) measured between the upper plane (48) and the lowest point (21) of the groove (17) is less than the vertical height (32) of the convex portion (29).

3. A panel (10) according to any one of the preceding claims, wherein The difference between the groove depth (20) and the vertical height (32) of the convex portion (29) is less than 1 mm.

4. A panel (10) according to any one of the preceding claims, wherein The cutout depth (23) is at least 0.1 mm greater than the vertical height (32) of the convex portion (29).

5. A panel (10) according to any one of the preceding claims, wherein The cutout (22) does not participate in the connection of the first pair of opposing edges (14, 15).

6. A panel (10) according to any one of the preceding claims, wherein The cutout (22) is located distally relative to the upper lip (19).

7. A panel (10) according to any one of the preceding claims, wherein The width of the cutout (22) is less than 0.5 mm, preferably less than 0.3 mm, more preferably less than 0.1 mm.

8. A panel (10) according to any one of the preceding claims, wherein The male coupling portion (28) and the female coupling portion (29) of the second pair of opposing edges (56, 57) comprise a tongue and a groove, respectively.

9. A panel (10) according to any one of the preceding claims, wherein The panel (10) comprises a floor panel, a ceiling panel or a wall panel.

10. A panel (10) according to any one of the preceding claims, wherein The panel (10) is a laminated panel or an elastic panel.

11. A panel (10) for forming a covering, the panel having an upper side (13) defining an upper plane (48), in, The panel (10) includes a first pair of opposing edges (14, 15) and a second pair of opposing edges (56, 57); the first pair of opposite edges (14, 15) being provided with a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18); the second pair of opposing edges (56, 57) being provided with coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposing edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposing edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); The tongue (16) further comprises a cutout (35) facing the recess (25), such that a vertical height (36) of the cutout (35) measured between the upper side (13) of the panel (10) and the highest point (46) of the cutout (35) is smaller than a vertical height (34) of the concave portion (28) measured between the highest point (37) of the concave portion (28) and the upper plane (48).

12. The panel (10) according to claim 11, wherein The depth (26) of the recess, measured between the upper side (13) of the panel (10) and the highest point (27) of the recess (25), is greater than the vertical height (34) of the concave portion (28).

13. The panel (10) according to any one of the preceding claims 11 to 12, wherein The difference between the recess depth (26) and the vertical height (34) of the concave portion (28) is less than 1 mm.

14. The panel (10) according to any one of the preceding claims 11 to 13, wherein The vertical height (36) of the cutout (35) is at least 0.1 mm smaller than the vertical height (34) of the concave portion (28).

15. The panel (10) according to any one of the preceding claims 11 to 14, wherein The cutout (35) does not participate in the connection of the first pair of opposing edges (14, 15).

16. The panel (10) according to any one of the preceding claims 11 to 15, wherein The width of the cutout (35) is less than 0.5 mm, preferably less than 0.3 mm.

17. The panel (10) according to any one of the preceding claims 11 to 16, wherein The male coupling portion (29) and the female coupling portion (28) of the second pair of opposing edges (56, 57) comprise a tongue and a groove, respectively.

18. The panel (10) according to any one of the preceding claims 11 to 17, wherein The panel (10) comprises a floor panel, a ceiling panel or a wall panel.

19. The panel (10) according to any one of the preceding claims 11 to 18, wherein The panel (10) is a laminated panel or an elastic panel.

20. A panel (10) for forming a covering, the panel having an upper side (13) defining an upper plane (48), in, The panel (10) includes a first pair of opposing edges (14, 15) and a second pair of opposing edges (56, 57); the first pair of opposite edges (14, 15) being provided with a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18), wherein the lower lip (18) extends distally beyond the upper lip (19); the second pair of opposing edges (56, 57) being provided with coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposing edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposing edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); in: The lower lip (18) includes a cutout (22) facing the groove (17) such that a depth (23) of the cutout measured between the upper plane (48) and the lowest point (24) of the cutout (22) is greater than a vertical height (32) of the convex portion (29) measured between the lowest point (32) of the convex portion (29) and the upper side (13) of the panel (10); and / or The tongue (16) further comprises a cutout (35) facing the recess (25), such that a vertical height (36) of the cutout (35) measured between an upper side (13) of the panel (10) and a highest point (46) of the cutout (35) is smaller than a vertical height (34) of the concave portion (28) measured between a highest point (37) of the concave portion (28) and the upper plane (48).

21. A method for designing a panel (10) having an upper side (13) defining an upper plane (48), in, The panel (10) includes a first pair of opposing edges (14, 15) and a second pair of opposing edges (56, 57), The first pair of opposite edges (14, 15) is provided with a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18), wherein the lower lip (18) extends distally beyond the upper lip (19), wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18), The second pair of opposing edges (56, 57) is provided with coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposing edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposing edges (56, 57), the method comprising: determining a groove depth (20) measured between the upper plane (48) and the lowest point (21) of the groove (17); determining a vertical height (32) of the convex portion (29) measured between the lowest point (33) of the convex portion (29) and the upper side (13) of the panel (10); determining a recess depth (26) measured between an upper side (13) of the panel (10) and a highest point (27) of the recess (25); determining a vertical height (34) of the concave portion (28) measured between a highest point (37) of the concave portion (28) and the upper plane (48); When the groove depth (20) is less than the vertical height (32) of the convex portion (29), adding a lower cutout (22) to the lower lip (18), the lower cutout (22) facing the groove (17) and having a depth (23) measured between the upper plane (48) and the lowest point (24) of the lower cutout (22), the depth of the lower cutout (22) being greater than the vertical height (32) of the convex portion (29); and When the recess depth (26) is greater than the vertical height (34) of the concave portion (28), an upper cutout (35) is added to the tongue (16), the upper cutout (35) facing the recess (25) and having a vertical height measured between the upper side (13) of the panel (10) and the highest point (46) of the upper cutout (35), the vertical height of the upper cutout being less than the vertical height (34) of the concave portion (28).

22. The method according to claim 21, wherein The difference between the groove depth (20) and the vertical height (32) of the convex portion (29) is less than 1 mm.

23. The method according to any one of the preceding claims 21 to 22, wherein The depth (23) of the lower cutout (22) is at least 0.1 mm greater than the vertical height (32) of the convex portion (29).

24. The method according to any one of the preceding claims 21 to 23, wherein The undercut (22) does not participate in the connection of the first pair of opposite edges (14, 15).

25. The method according to any one of the preceding claims 21 to 24, wherein The difference between the recess depth (26) and the vertical height (34) of the concave portion (28) is less than 1 mm.

26. The method according to any one of the preceding claims 21 to 25, wherein The vertical height (36) of the upper cutout (35) is at least 0.1 mm smaller than the vertical height (24) of the concave portion (28).

27. The method according to any one of the preceding claims 21 to 26, wherein The upper cutout (35) does not participate in the connection of the first pair of opposite edges (14, 15).

28. The method according to any one of the preceding claims 21 to 27, wherein The width of the upper incision (35) is less than 0.5 mm.

29. The method according to any one of the preceding claims 21 to 28, wherein The width of the lower cutout (22) is less than 0.5 mm, preferably less than 0.3 mm.

30. The method according to any one of the preceding claims 21 to 29, wherein The male coupling portion (29) and the female coupling portion (28) of the second pair of opposing edges (56, 57) comprise a tongue and a groove, respectively.

31. A method for manufacturing a panel (10), the method comprising: advancing a panel (10) having an upper side (13) defining an upper plane (48) relative to a first milling device having at least two milling tools; processing a first pair of opposite edges (14, 15) of the panel (10) by means of at least two milling tools of the first milling device to form a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18), wherein the lower lip (18) extends distally beyond the upper lip (19); advancing the panel (10) relative to a second milling device having at least two milling tools; processing a second pair of opposite edges (56, 57) of the panel (10) by means of at least two milling tools of the second milling device to form coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein the tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); in: The lower lip (18) includes a cutout (22) facing the groove (17) such that a depth (23) of the cutout measured between the upper plane (48) and the lowest point (24) of the cutout (22) is greater than a vertical height (32) of the convex portion (29) measured between the lowest point (32) of the convex portion (29) and the upper side (13) of the panel (10); and / or The tongue (16) further comprises a cutout (35) facing the recess (25), such that a vertical height (36) of the cutout (35) measured between an upper side (13) of the panel (10) and a highest point (46) of the cutout (35) is smaller than a vertical height (34) of the concave portion (28) measured between a highest point (37) of the concave portion (28) and the upper plane (48).

32. The method according to claim 31, wherein The difference between the groove depth (20) and the vertical height (32) of the convex portion (29) is less than 1 mm.

33. The method according to any one of the preceding claims 31 to 32, wherein The depth (23) of the lower cutout (22) is at least 0.1 mm greater than the vertical height (32) of the convex portion (29).

34. A method according to any one of claims 31 to 33, wherein The undercut (22) does not participate in the connection of the first pair of opposite edges (14, 15).

35. The method according to any one of the preceding claims 31 to 34, wherein The difference between the recess depth (26) and the vertical height (34) of the concave portion (28) is less than 1 mm.

36. A method according to any one of claims 31 to 35, wherein The vertical height (36) of the upper cutout (35) is at least 0.1 mm smaller than the vertical height (34) of the concave portion (28).

37. A method according to any one of claims 31 to 36, wherein The upper cutout (35) does not participate in the connection of the first pair of opposite edges (14, 15).

38. A method according to any one of claims 31 to 37, wherein The width of the upper cutout (35) is less than 0.5 mm, preferably less than 0.3 mm.

39. The method according to any one of the preceding claims 31 to 38, wherein The width of the lower cutout (22) is less than 0.5 mm, preferably less than 0.3 mm.

40. The method according to any one of the preceding claims 31 to 39, wherein The male coupling portion (29) and the female coupling portion (28) of the second pair of opposing edges (56, 57) comprise a tongue and a groove, respectively.

41. A method for manufacturing a panel (10), the method comprising: advancing a panel (10) having an upper side (13) defining an upper plane (48) relative to a first milling device having at least two milling tools; processing a first pair of opposite edges (14, 15) of the panel (10) by means of at least two milling tools of the first milling device to form a coupling portion in the form of a tongue (16) at one edge (14) of the first pair of opposite edges (14, 15) and a groove (17) at the other edge (15) of the first pair of opposite edges (14, 15), the groove (17) being delimited by an upper lip (19) and a lower lip (18); advancing the panel (10) relative to a second milling device having at least two milling tools; processing a second pair of opposite edges (56, 57) of the panel (10) by means of at least two milling tools of the second milling device to form coupling portions in the form of a male coupling portion (29) at one edge (56) of the second pair of opposite edges (56, 57) and a female coupling portion (28) at the other edge (57) of the second pair of opposite edges (56, 57); wherein, during processing of a corner region defined by an overlapping portion of one edge of the first pair of opposing edges (14, 15) and one edge of the second pair of opposing edges (56, 57), at least two milling tools of the first milling device and / or at least two milling tools of the second milling device are moved in a vertical direction relative to the upper side (13) of the panel (10) so as to remove or prevent the formation of a corner segment.

42. The method according to claim 41, wherein The groove depth (20) measured between the upper plane (48) and the lowest point (21) of the groove (17) is less than the vertical height (32) of the convex portion (29) measured between the lowest point (32) of the convex portion (29) and the upper side (13) of the panel (10).

43. The method according to any one of the preceding claims 41 to 42, wherein The difference between the groove depth (20) and the vertical height (32) of the convex portion (29) is less than 1 mm.

44. A method according to any one of claims 41 to 43, wherein The tongue (16) defines a recess (25) opposite the upper side (13) of the panel (10) and configured to receive a portion of the lower lip (18); wherein a depth (26) of the recess measured between an upper side (13) of the panel (10) and a highest point of the recess (25) is greater than a vertical height (34) of the recess (28) measured between a highest point (37) of the recess (28) and the upper plane (48).

45. The method according to any one of the preceding claims 41 to 44, wherein The difference between the recess depth (26) and the vertical height (34) of the concave portion (28) is less than 1 mm.

46. A method according to any one of claims 31 to 45, wherein The male coupling portion (29) and the female coupling portion (28) of the second pair of opposing edges (56, 57) comprise a tongue and a groove, respectively.

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