Method for producing a decorative panel and decorative panel obtained thereby

Abstract

The invention relates to a method for producing decorative panels, comprising at least:-providing a plate-like material (17) having a base plate (7) and a top layer; -providing a reduced region (6A) in the plate-like material (17); further processing the plate-like material (17) into one or more of the plurality of decorative panels (1); the method is characterized in that one or more lowered areas (6A) are provided at least by means of a pressing tool (22) which comprises at least a first projection (57) corresponding to the position of the lowered area (6A) and at least a second projection (84) corresponding to the portion of the plate-like material (17) removed in the further processing step.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a decorative panel and to a decorative panel obtained thereby.

[0002] The present invention particularly relates to a method for manufacturing a decorative panel comprising a lowered edge region, for example in the form of a bevel, at one or both of a pair of opposite edges. The decorative panel can have a substrate and a top layer applied to the substrate, the top layer comprising at least a printed pattern and a transparent layer applied to the printed pattern. Preferably, the printed pattern extends continuously from the overall upper surface of the panel towards and over the lowered edge region. The transparent layer can also be provided with recesses, for example for imitating wood pores. BACKGROUND

[0003] Methods for manufacturing decorative panels with lowered edge regions are known, for example from WO 2006 / 066776 and WO 2022 / 238858. Here, a larger blank, panel or sheet is first provided which is provided with a lowered region. However, after forming the lowered region corresponding to the lowered edge region, it can be difficult to further process such a blank, panel or sheet correctly. Splitting the larger blank, panel or sheet into panels having the approximate final size of the decorative panels to be obtained can result in the entire lowered region being removed, or in the lowered edge region not showing the desired dimensions. Milling the panels to form the edges can lead to similar undesirable results. Forming the lowered region can result in a larger deformation of the substrate of the blank, panel or sheet, leading to defects.

[0004] It is also known from WO 2022 / 101743, for example, to provide recesses in the transparent layer with an additional component. Here, the additional component is applied to the upper surface of the transparent layer. However, some difficulties can arise when providing the additional component on a blank, sheet or panel-like material provided with a lowered region, for example a lowered region such as taught in WO 2006 / 066776 and WO 2022 / 238858. SUMMARY

[0005] It is an object of the present invention to provide an alternative method for manufacturing a decorative panel, wherein, according to a preferred embodiment, one or more problems of the prior art methods are solved.

[0006] To achieve this object, the present invention according to its first independent aspect is a method for manufacturing a decorative panel, wherein the method at least comprises: - a step of providing a blank, sheet or panel-like material comprising a substrate and a top layer applied to the substrate, the top layer comprising at least a printed pattern and a transparent layer applied to the printed pattern; - a step of providing one or more lowered areas in the slab, sheet or board material; - a step of further processing, preferably at least dividing, the slab, sheet or board material into one or more of the decorative panels, wherein at least a part of the one or more lowered areas forms a lowered edge area at one or both of the pair of opposite edges of the decorative panel; characterized in that the step of providing one or more lowered areas in the slab, sheet or board material comprises at least a preferably non-continuous pressing operation by means of a press having a pressing die, wherein at least a reference edge is machined on the substrate prior to and / or during and / or after the pressing operation, wherein the reference edge is at a predetermined distance from and preferably parallel to at least one of the pair of opposite edges or at least one upper edge. The reference edge can be used in the further processing step such that the lowered edge area has a repeatable and / or predetermined dimension.

[0007] Preferably, the step of providing the slab, sheet or board material comprises first providing the material in a continuous form and cutting the material transversely, e.g. by means of a cutting device, e.g. by means of a punch press, a guillotine or a flying saw, to at least the substrate. Preferably, the transverse cutting is performed while the material in the continuous form is continuously fed in its longitudinal direction. Potentially, the material in the continuous form can be temporarily obstructed by the cutting device. The transverse cutting operation can in particular be prone to inaccuracies and / or lack of perpendicularity. It is in this case that the present invention is in particular interesting according to its first independent aspect. The machined reference edge can be used in the further processing instead of the edge resulting from the transverse cutting.

[0008] Preferably, the material in the continuous form comprises at least the substrate and a top layer.

[0009] Preferably, the material in the continuous form is provided at least by extrusion and preferably a top layer is subsequently provided on the extruded material, e.g. by means of a hot lamination of one or more pre-made sheets of e.g. a printed decorative foil and a transparent foil. Alternatively, a printed pattern is provided on the extruded material by applying an ink directly on the extruded material, potentially with an intermediate layer of one or more primer layers, and / or a transparent layer is provided on the printed pattern by applying a varnish or a polymeric substance in a liquid manner.

[0010] Preferably, the slab, sheet or board material is provided with a first edge that is at least machined straight. The first edge can be provided along the extrusion direction. For example, a cutting device, such as a knife, can be positioned at the first longitudinal edge and the material in the continuous form can be continuously fed along and over the cutting device.

[0011] Preferably, the at least one straightened edge forms a first reference edge and is, for example, used for aligning the slab to the press mould. Preferably, the slab, sheet or plate-like material is driven into the press by means of a carriage and / or gripper, wherein the slab, sheet or plate-like material is fed into the press with the first reference edge in a predetermined position, wherein, for example, a precision is allowed which allows a tolerance of 0.25 mm or less.

[0012] Preferably, the slab, sheet or plate-like material is provided with at least one second edge which is straightened by processing, wherein the second edge is perpendicular to the first edge. Preferably, the second straightened edge is provided in a device in which the first straightened edge is used as a reference. Preferably, the second straightened edge is provided when the slab, sheet or plate-like material is fed into the press, when the slab, sheet or plate-like material is in the press, and / or when the slab, sheet or plate-like material leaves the press. In this case, the second reference edge can be provided perpendicular to the first reference edge in a sufficiently precise manner.

[0013] Preferably, the one or more reference edges are used as a reference for dividing the slab, sheet or plate-like material. Preferably, the slab, sheet or plate-like material is divided into panels having approximately the desired dimensions of the decorative panel.

[0014] Preferably, the one or more reference edges are used as a reference in further processing. Preferably, the further processing at least comprises providing (more specifically milling out) a shaped edge on a pair of opposite edges. Preferably, it involves that the shaped edge is provided with a coupling portion, thereby allowing coupling of two such decorative panels at the respective edges and, in the coupled state, achieving a locking in a direction perpendicular to the plane of the coupled panel and / or in the plane and perpendicular to the respective edge.

[0015] Preferably, the method further comprises the step of providing a recess in the transparent layer, wherein preferably this step is at least partially performed separately from, preferably before, the step of providing a lowered area in the slab, sheet or plate-like material. During the step of providing a lowered area in the slab, sheet or plate-like material, the transparent layer can be provided with the recess, such that the step of providing a lowered area in the slab, sheet or plate-like material and the step of providing a recess in the transparent layer can be one and the same step.

[0016] Preferably, the substrate comprises a filled synthetic composite material, which at least comprises a synthetic material and a filler material, wherein preferably the synthetic material is a thermoplastic material, such as polyvinyl chloride and / or polypropylene and / or polyethylene terephthalate and / or glycol-modified polyethylene terephthalate, and the filler material can be calcium carbonate and / or talc and / or chalk and / or limestone and / or coal. Preferably, the weight ratio of the filler material to the synthetic material is at least 2:1, or at least 3:1, or at least 4:1. In case polyvinyl chloride is used as the thermoplastic material, or in other cases where other thermoplastic materials are used, the synthetic material composite preferably does not contain plasticizer or contains a plasticizer in an amount of 5 phr or less. It is precisely for these composites that the present invention is particularly relevant in accordance with its first independent aspect, as such composites can be particularly susceptible to dimensional instability and deformation due to temperature changes. Precision-enhanced management of the manufacturing of the panel with a lowered edge region in accordance with the reference edge provided according to the present independent aspect can alleviate problems associated with such deformations.

[0017] It is noted that the present invention also relates to a decorative panel obtained by a method having the features of the first independent aspect and / or its preferred embodiments.

[0018] As described in the context of the first independent aspect, preferably the provision of the recess in the transparent layer is performed at least partially separately from the provision of the lowered region in the blank, sheet or board-like material. This order of manufacturing steps is equally important independent of the use of the reference edge. Thus, the present invention is in accordance with its second independent aspect a method for manufacturing a decorative panel, wherein the method comprises: - a step of providing a blank, sheet or board-like material comprising a substrate and a top layer applied on the substrate, the top layer at least comprising a printed pattern and a transparent layer applied on the printed pattern; - a step of providing a recess in the transparent layer; - a step of providing one or more lowered regions in the blank, sheet or board-like material; wherein the blank, sheet or board-like material is optionally heated to a temperature between 25 °C and 110 °C (e.g. between 85 °C and 105 °C or between 90 °C and 100 °C) prior to the step of providing the lowered region; - a step of further processing (preferably segmenting) the blank, sheet or board-like material into one or more of the plurality of decorative panels, wherein at least a portion of the one or more lowered regions forms a lowered edge region at one or both of the pair of opposite edges of the decorative panel; wherein, - the step of providing the recess in the transparent layer is at least partially performed separately from the step of providing the lowered area in the slab, sheet or plate-like material, preferably before this step.

[0019] The inventors have surprisingly found that forming the recess and providing the lowered area separately does not necessarily have a negative impact on the achievable embossing resolution. For example, in case the recess is provided prior to the step of providing the lowered area, the inventors have noticed that the sharpness of the recess is not affected and that the recess does not fade due to the subsequent provision of the lowered area. Forming the recess and providing the lowered area separately allows for a flexible manufacturing process, wherein potentially the same slab, sheet or plate-like material can be provided with or without a lowered area depending on the selection.

[0020] Preferably, the step of providing the recess in the transparent layer is at least partially performed by an embossing roll, wherein preferably the embossing roll is heated to a temperature in the range of 140 °C to 180 °C. The inventors have found that at this temperature range the structure of the embossing roll fits better into the transparent layer. The flowability of the material of the transparent layer is enhanced by the temperature increase such that the material better replicates the relief features of the embossing roll such that also the smallest relief features are well replicated into the transparent layer. This has been found to be especially true for transparent layers comprising or based on thermoplastic material, for example transparent layers based on (whether or not plasticized) polyvinyl chloride (PVC). In case an embossing roll is used to provide the recess in the transparent layer, preferably the slab, sheet or plate-like material is provided in a continuous form.

[0021] In a preferred embodiment of the application, the slab, sheet or plate material is preheated by radiation and / or convection, or comprises residual heat from a processing step preceding the step of providing one or more lowered areas. The residual heat can for example be from a processing step preceding the step of providing one or more lowered areas, such as a lamination and / or embossing processing step, etc. Raising the temperature of the slab, sheet or plate material enables better thermoplastic deformation. Preferably, the preheating raises the temperature of the slab, sheet or plate material (in particular the surface temperature of the slab, sheet or plate material provided with the printed pattern and the transparent wear layer) to between 25 °C and 110 °C. More preferably, the preheating reaches a temperature of between 55 °C and 95 °C, for example about 60 °C or about 80 °C. Alternatively, the preheating reaches a temperature of between 80 °C and 110 °C, or between 85 °C and 105 °C. In this case, the slab, sheet or plate material can need to take additional measures, such as one or more support elements, to be transported into the press, as it can have become quite flexible and plastic. However, the inventors found that preheating to above 80 °C minimizes the risk of defects occurring during pressing, such as local stress zones. Preferably, such preheating above 80 °C (for example about 90 °C to about 100 °C) is combined with a press having a temperature below 50 °C, even below 40 °C. The press can be unheated, or even cooled.

[0022] It should be noted that the temperature reached in the preheating is preferably defined by the temperature of the side of the slab, sheet or plate material to be provided with lowered areas.

[0023] The step of providing one or more lowered areas can be realized according to a variety of possibilities, four of which are further described below, which are not exhaustive.

[0024] According to a first possibility, the step of providing one or more lowered areas is performed by a press, preferably a discontinuous press, and the press is heated to a temperature, preferably in the range of 75°C to 150°C or 100°C to 150°C. The press of the first possibility, preferably a discontinuous press, preferably comprises a press die having a die portion, wherein the die portion has an overall surface comprising at least one protrusion contacting the slab, sheet or board material during the pressing operation, preferably on that part of the press die surface, wherein the protrusion at least corresponds to the position of the lowered area. For example, the press die comprising the die portion having one or more protrusions can be at a temperature of 75°C to 100°C, for example 85°C to 90°C. It is possible to provide a further press die, whether or not having a texture, which is arranged opposite the press die, wherein the further press die is configured for contacting the bottom of the slab, sheet or board material. Preferably, the further press die is at a lower temperature than the press die comprising the die portion having one or more protrusions. For example, the further press die can be at a temperature of 35°C to 60°C, for example about 50°C. The slab, sheet or board material, in particular its upper surface, can also be heated prior to the step of providing the lowered area, for example by means of radiation and / or convection, more in particular to a temperature in the range of 25°C to 110°C, or preferably 55°C to 95°C, for example about 60°C or about 80°C. Another possible way of heating the slab, sheet or board material prior to the step of providing the lowered area is by closing the press onto the slab, sheet or board material, preferably without applying pressure to provide the lowered area, such that the slab, sheet or board material is heated by the heat provided by the press. The inventors found that the closing of the press for the purpose of heating the slab, sheet or board material is preferably maintained for about 4 seconds to 10 seconds, for example for about 7 seconds. Subsequently, pressure can be applied to provide the lowered area.

[0025] As previously mentioned, the press of the first possibility, preferably a discontinuous press, preferably comprises a pressing die having a die portion, wherein the die portion has an overall surface which preferably comprises at least one protrusion on that part of the die surface which contacts the blank, sheet or board material during the pressing operation, characterized in that the protrusion at least corresponds with the location of the lowered area. Even more preferably, in case of a lowered area for forming a lowered edge area at a longitudinal edge of the decorative panel, the length of the protrusion(s) is greater than or equal to the length of the blank, sheet or board material, and / or in case of a lowered area for forming a lowered edge area at a transverse or short edge of the decorative panel, the length of the protrusion(s) is greater than or equal to the width of the blank, sheet or board material, wherein in this case the length direction of the blank, sheet or board material preferably coincides with the direction of the longitudinal edge of the decorative panel. The inventors found that a reduction of local stress zones in the pressed area of the blank, sheet or board material can be obtained. Local stress zones can originate from a shearing action of the protrusion on the blank, sheet or board material and can negatively influence the overall performance of a coupling mechanism possibly provided on the decorative panel.

[0026] The protrusion(s) preferably extend from an adjacent part of the overall surface of the die portion and the height of the protrusion(s) is greater than the depth of the lowered area. The inventors found that the protrusion(s) preferably extend from an adjacent part of the overall surface with a height of 2 to 4 mm, measured from the overall surface to the most distant point of the respective protrusion. Alternatively, the protrusion(s) preferably extend from an adjacent part of the overall surface of the die portion and the height of the protrusion(s) is greater than 35% or even greater than 50% of the thickness of the blank, sheet or board material. The inventors noticed that surprisingly, in this case, the recess performed before forming the lowered area does not completely or partially disappear. It was further found that even if some spring back, i.e. a reduction of the originally obtained depth, can occur after forming the lowered area, with the lowered area formed by means of a protrusion having this extent, a significant lowered edge area can still be obtained at the decorative panel.

[0027] The pressure applied by the discontinuous press is preferably in the range of 10 kg / cm 2 to 40 kg / cm 2 .

[0028] According to a particular embodiment of this first possibility, the recesses can at least partially be formed by the press, preferably a discontinuous press. According to an alternative, the recesses are pre-formed by means of a stamping roller, wherein the final shape, size or form of the recesses is obtained in the press.

[0029] According to a second possibility, the step of providing a lowered area is performed at a temperature in the range of 25°C to 75°C (or 25°C to 50°C, for example about 30°C to about 40°C) by means of a press, preferably a non-continuous press. The press can be non-heated, i.e. can be at ambient temperature, or can even be cooled. The press of the first possibility, preferably a non-continuous press, preferably comprises a pressing die having a die part, wherein the die part has an overall surface which preferably comprises at least one protrusion on that part of the pressing die surface which contacts the slab, sheet or board material during the pressing operation, wherein the protrusion at least corresponds to the location of the lowered area. The pressing die having a die part with one or more protrusions preferably forms the upper platen, and can be heated in the same temperature range as a potentially further pressing die, whether or not having a texture, which is arranged opposite to the pressing die and is configured for contacting the bottom of the slab, sheet or board material. Both pressing dies can for example be heated in the range of 25°C to 50°C (for example about 30°C to about 40°C). Preferably, the slab, sheet or board material is subsequently heated to a temperature in the range of 60°C to 110°C, 85°C to 105°C or 95°C to 110°C. The slab, sheet or board material can be heated according to the means described in the first possibility of providing one or more lowered areas, and / or can be heated by means of radiation and / or convection. One problem that can occur is that when a pressing operation with ill-chosen processing parameters such as pressing temperature and substrate temperature sets a lowered area on a decorative panel, the lowered area can at least partially spring back when exposed to temperatures above 30°C for a long period of time. By providing one or more lowered areas in a heated slab, sheet or board material by means of a press with a temperature in the range of 25°C to 75°C, preferably about 60°C or even lower, about 30°C to about 40°C, the inventors found that the lowered area better retains its depth when used for a long time at temperatures above 30°C. It is assumed that pre-heating the slab, sheet or board material in the range of 60°C to 110°C, above 80°C or 85°C, or 95°C to 110°C brings the slab, sheet or board material into a plastic state. Then, performing the pressing treatment at a lower temperature, for example at ambient temperature, for example about 25°C to 35°C, will fix the slab, sheet or board material in the desired deformed state. The inventors have noticed that the lowered areas formed in this way have a lower tendency to spring back even at high temperatures during use. Potential defects such as local stress zones due to the deformation of the slab, sheet or board material can be less severe in these cases. Due to the colder pressing treatment, the slab, sheet or board material after pressing is easier to handle after pressing.

[0030] According to the first and second possibilities, the temperature of the press is preferably defined by the temperature of the upper platen or upper press mold forming the mold portion with one or more protrusions in the case of a discontinuous press. The discontinuous press can comprise a lower platen for contacting the bottom surface of the slab, sheet or board, which can or can not have a structured surface. In the case of the first and second possibilities, the temperatures of the upper and lower platens can be equal or approximately equal. This temperature corresponds to the temperature of the press mentioned in the first and second possibilities. Alternatively, the temperatures of the upper and lower platens can be different. The temperature of the platen or press mold having a mold portion with one or more protrusions corresponds to the temperature of the press mentioned in the first and second possibilities. In the case of a continuous press, the temperature of the press is defined by the temperature of the platen element having one or more protrusions, such as a platen roller or a platen belt.

[0031] It should be noted that any structure on the lower platen or on the press mold opposite to the press mold having a mold portion with one or more protrusions preferably has protrusions, if any, with a height everywhere less than the maximum height of the protrusions on the upper platen. Preferably, the height of the protrusions on the lower platen is everywhere less than 25% of the maximum height of the protrusions on the upper platen. The protrusions on the lower platen can provide a functional or decorative relief at the bottom of the slab, sheet or board-shaped material. For example, such protrusions can provide a relief with anti-slip properties or a relief enhancing the adhesion by means of glue, such as the glue of the backing layer.

[0032] According to a variant of the first and second possibilities, the slab, sheet or board-shaped material is heated, for example by means of infrared heaters, prior to the step of heating the lowered area to a preheating temperature of 50°C to 90°C, preferably about 80°C. The platens of the discontinuous press, i.e. the upper platen or upper press mold forming the mold portion with one or more protrusions and the lower platen for contacting the bottom surface of the slab, sheet or board, can be at mutually different temperatures. According to a first example, the upper platen temperature is higher than the lower platen temperature. For example, the upper platen temperature can be above 100°C, for example about 120°C, while the lower platen temperature can be below 120°C, for example about 100°C. According to a second and particularly preferred possibility, the upper platen temperature is lower than the lower platen temperature. For example, the upper and lower platens can be at an upper platen temperature below 100°C, even below 80°C, or below 60°C, and the lower platen temperature is above 60°C, even above 80°C, or about 100°C, respectively. A particularly preferred upper platen temperature is about 50°C, while the lower platen temperature is about 100°C.

[0033] In the first possibility and the second possibility and in the variants, it is preferred that the maximum pressure applied by the discontinuous press is established quickly, for example within a time period of 10 seconds or less, preferably 5 seconds or less. As mentioned before, the maximum pressure can be in the range of 10 kg / cm 2 to 40 kg / cm 2 . The maximum pressure can be maintained for 2 to 10 seconds, for example for about 5 seconds. The inventors found that the best results are achieved when the maximum pressure is maintained for 2 to 7 seconds, after which the pressure is reduced to maintain this reduced pressure value (for example half of the maximum pressure or less) for 2 to 15 seconds (preferably 2 to 7 seconds), in particular when the variants of the first and second possibilities are implemented. A first preferred setting is as follows: preheating to 80°C; upper platen temperature of 50°C; lower platen temperature of 100°C; maximum pressure of 35 kg / cm 2 and maintained for 5 seconds, and in the subsequent pressing phase a reduced pressure of 10 kg / cm 2 is maintained for 5 seconds; after which the pressure is completely released and the board blank, sheet or board-like material is removed from the discontinuous press. The establishment time to reach the maximum pressure is less than 5 seconds, even 2 seconds or less. A second preferred setting is as follows: preheating in the range between 90°C and 100°C; upper and lower platen temperature of 25°C or ambient temperature; maximum pressure of 15 kg / cm 3 and maintained for 3 seconds, and in the subsequent pressing phase a reduced pressure of 5 kg / cm 3 is maintained for 12 seconds; after which the pressure is completely released and the board blank, sheet or board-like material is removed from the discontinuous press. The establishment time to reach the maximum pressure is less than 5 seconds, even 2 seconds or less.

[0034] It is noted that heating the board blank, sheet or board-like material prior to the step of providing the reduced area can enhance the repeatability of providing the reduced area. When the temperature of each board blank, sheet or board-like material is recorded and / or the temperature is equal when the reduced area is provided, the position of the reduced area in the board blank, sheet or board-like material is known and / or constant. The subsequent finishing steps or sub-steps of converting the board blank, sheet or board-like material into a decorative panel can be performed more accurately, while the likelihood of inadvertently removing the reduced area or parts thereof is reduced. The temperature management of the board blank, sheet or board-like material when the reduced area is provided is especially useful in combination with the reference edge mentioned in the context of the first aspect. The temperature management contributes to defining the distance of the reference edge from at least one upper edge of the pair of opposite edges. This distance is set at the preheating temperature and known, as it is defined by the die part or the platen element (for example the upper platen in the press). With the thermal expansion behavior of the board blank, sheet or board-like material, the distance at other temperatures can be accurately calculated and taken into account in this finishing step.

[0035] In the first possibility as well as in the second possibility, the one or more protrusions providing the lowered area preferably exhibit one or more of the following properties: - the one or more protrusions comprise a property of a first side portion of the surface forming the lowered edge area, wherein the first side portion is curved, preferably concavely curved, and has a radius of between 2 mm and 10 mm; - the one or more protrusions have a property of a maximum height position, wherein the position is located on a rounding segment having a radius of between 0.2 mm and 1 mm; - the one or more protrusions have a property of a maximum height, wherein the maximum height is between 0.75 mm and 1.5 mm; - the one or more protrusions comprise a property of a first side portion of the surface forming the lowered edge area and a second side portion opposite the first side portion, wherein the second side portion forms an angle of 110° to 145° with the overall surface of the pressing tool; - the above four properties in combination, wherein the cross-section of the one or more protrusions is essentially defined by the first side portion, the rounding segment and the second side portion.

[0036] In the first possibility as well as in the second possibility, the step of providing one or more lowered areas in the slab, sheet or plate-like material comprises at least a pressing operation, preferably a non-continuous pressing operation, by means of a press. Preferably, the press comprises a pressing tool, wherein the pressing tool comprises at least a first protrusion on a portion of the tool surface contacting the slab, sheet or plate-like material, wherein the first protrusion at least corresponds to the position of at least one of the plurality of lowered areas, wherein the pressing tool comprises at least a second protrusion extending substantially parallel to the first protrusion, wherein the second protrusion contacts the slab, sheet or plate-like material during the pressing operation and corresponds to the portion of the slab, sheet or plate-like material which is removed in the finishing step. As further explained in the ninth independent aspect of the present invention, such a second protrusion can minimize the occurrence of local stress areas of the slab-like material at the position of the material pressed by means of the first protrusion.

[0037] In some embodiments of the first possibility as well as of the second possibility, in particular in case the temperature of the press is lower than the pre-heating temperature of the slab, sheet or plate-like material, the pressing tool at least having a tool portion with one or more protrusions forming the lowered areas can be actively cooled. In this case, a gradual heating of the pressing tool by contacting the pre-heated slab, sheet or plate-like material can be avoided or minimized.

[0038] According to a third possibility, the step of providing one or more lowered areas is performed by means of an impression roller, and the impression roller is preferably heated, for example to a temperature in the range of 130°C to 180°C. It should be noted that in case the impression roller is employed to form the recesses in the transparent layer, the impression roller for providing one or more lowered areas can be a further impression roller. In case the lowered areas are provided by means of an impression roller, preferably the web, sheet or board material is provided in a continuous form.

[0039] The impression roller comprises a circumference comprising at least one protrusion corresponding to the position of at least one of the lowered areas.

[0040] The one or more protrusions preferably extend from adjacent portions of the circumference, the height of the one or more protrusions being greater than the depth of the lowered areas. The depth preferably corresponds to the vertical distance measured from the highest point of the overall upper surface of the web, sheet or board material to the lowest point of the lowered areas provided on the web, sheet or board material, wherein the measurement is made after the web, sheet or board material provided with lowered areas is conditioned to room temperature and any spring back has occurred. By forming the lowered areas with such a degree of protrusion, a significant drop edge area can be obtained at the decorative panel.

[0041] According to a fourth possibility, the recesses are at least partially formed by means of an impression roller, wherein the one or more lowered areas are also partially formed by means of the impression roller. The impression roller can be pre-formed with the one or more lowered areas to facilitate the pressing operation, for example according to the first possibility or alternative, further in the production process. Preferably, the one or more lowered areas are pre-formed on the web, sheet or board material provided in a continuous form by means of the impression roller.

[0042] The web, sheet or board material comprises a bottom, wherein the bottom preferably comprises the underside of the substrate or the underside of the backing layer. Preferably, the bottom comprises one or more recesses.

[0043] In case a backing layer is present, preferably the backing layer comprises a thermoplastic material. The backing layer can be used for a variety of reasons, for example but not limited to shock absorbing purposes, anti-slip, noise reduction, etc.

[0044] Preferably, the method comprises the step of adding one or more recesses to the bottom, and this step is at least partially performed by means of an impression roller or a discontinuous press. Another possibility is to at least partially mill and / or saw out the bottom recesses. In case of the above first possibility, the discontinuous press can be the same discontinuous press as used for forming the lowered areas or can be a further discontinuous press. The provision of these recesses at the bottom can result in a lighter weight of the decorative panel, or a lighter weight to thickness ratio, compared to a decorative panel without these recesses provided at the bottom.

[0045] The slab, sheet or board material preferably comprises one or more technical areas which are at least partially removed during a further processing step, i.e. preferably in a step of dividing the slab, sheet or board material into one or more decorative panels. Technical areas in a technical sense mean that the material is at least partially not present in the area in the one or more decorative panels, preferably floor panels. It can thus be clear that the slab, sheet or board material preferably comprises material of a plurality of adjacent decorative panels, wherein in a further processing step, the technical areas between the decorative panels need to be at least partially removed.

[0046] In a preferred embodiment of the application, the method comprises the step of providing one or more technical areas with one or more recesses, wherein the recesses can be present at the bottom side and / or the top of the slab, sheet or board material. Preferably, the step of providing recesses in the one or more technical areas is at least partially performed before the step of providing one or more lowered areas into the slab, sheet or board material.

[0047] The recesses in the technical areas can be used for the formation of the lowered areas. The inventors have found that during embossing and / or pressing of the thermoplastic material, the embossed and / or pressed material will displace rather than be compressed. By providing areas without material, the embossed / pressed material has space to displace into, without accumulating too much additional stress in other areas of the slab, sheet or board material.

[0048] The recesses in the one or more technical areas are preferably at least partially provided by milling and / or sawing and / or cutting, but can also at least partially be provided by means of embossing and / or pressing. Another possibility is that the recesses in the one or more technical areas are provided by means of extrusion by means of a die with adapted slot nozzle openings.

[0049] It should be noted that the approach of providing lowered areas in the slab, sheet or board material according to one or more of the possibilities described in the context of the second aspect is meaningful per se, regardless of whether recesses have been formed in the transparent layer and / or whether the formation of such potential recesses is performed before and / or separately from the step of providing lowered areas into the slab, sheet or board material. In particular in the first and second possibilities and their variants, the pre-heating step and the specific temperature and / or pressure regime described therein bring important advantages, for example in terms of limiting spring-back and reducing the severity of local stress zones, even when no recesses are formed, or when the formation of these recesses is not performed separately from and / or before the step of providing the lowered areas.

[0050] As mentioned above, the step of providing one or more lowered areas in the slab, sheet or board material is preferably later than the step of pre-heating the slab, sheet or board material. This pre-heating can be performed by means of any heating device, such as a hot air oven, radiation or convection heating. Preferably, this pre-heating is performed by contacting one side of the slab, sheet or board material, preferably the bottom side, with a heating table or plate, for example a heated aluminium plate, while the other side, preferably the side to be provided with one or more lowered areas, is heated by means of radiation, for example by means of infrared radiation. Preferably, the temperature on at least the side of the slab, sheet or board material to be provided with one or more lowered areas is monitored, wherein this temperature defines the pre-heating temperature. The temperature of the heating table or plate can be kept between 80% and 110% of the target pre-heating temperature.

[0051] As mentioned in the context of the second implementation of the lowered area for the second independent aspect, the one or more lowered areas are preferably provided by means of a heated embossing roll. The hot embossing of the lowered area is of particular importance, whether or not the recess is formed separately. Further temperature management during further processing of the slab, sheet or board material can improve the accuracy of the manufacturing method. It should thus be noted that the present invention according to its third independent aspect is a method for manufacturing a decorative panel, wherein the method comprises: - a step of providing a slab, sheet or board material comprising a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern; - a step of providing one or more lowered areas in the slab, sheet or board material; - a step of further processing, preferably segmenting, the slab, sheet or board material into one or more of the plurality of decorative panels, wherein at least a portion of the one or more lowered areas forms a lowered edge area at one or both of the pair of opposite edges of the decorative panel; wherein, - the step of providing one or more lowered areas in the slab, sheet or board material is performed using an embossing roll at a temperature of 130°C or higher, preferably less than 200°C, preferably about 170°C, wherein preferably the surface of the slab, sheet or board material has been pre-heated; and / or - the slab, sheet or board material is provided in a continuous form, wherein the further processing step comprises: cutting the slab, sheet or board material transversely as a first operation after the step of providing the lowered areas, and / or within 10 m of providing the lowered areas, and / or at a temperature of 100°C or higher, preferably 200°C or higher, for example about 240°C to 250°C.

[0052] The inventors have found that by using an embossing roller with a temperature of 130 °C or above, preferably between 130 °C and 200 °C, the structure of which is better adapted to the transparent layer, one or more lowered areas can be provided in the web, sheet or plate material. The enhanced flowability of the material of the transparent layer better replicates the relief of the embossing roller, such that even the smallest relief features are well replicated.

[0053] The inventors have also found that, after the step of providing the lowered areas, preheating the web, sheet or plate material after cooling the web, sheet or plate material to room temperature, results in the lowered areas having a minimal residual shrinkage and minimal distortion. The inventors have also noticed that cutting the preheated web, sheet or plate material better allows the web, sheet or plate material to relax, resulting in less residual shrinkage and / or distortion.

[0054] It will be clear from the above that the features listed under the third independent aspect do not necessarily need to be used in combination in the manufacturing method, but both the use of a heated embossing roller and the hot cutting of the web, sheet or plate material have independent technical importance.

[0055] Preferably, the transparent layer is at least partially coated prior to the step of providing one or more lowered areas. Also preferably, the web, sheet or plate material is provided in a continuous form.

[0056] In a preferred embodiment of the application, the embossing roller is used together with a counter roller. The counter roller preferably comprises a rubber or synthetic circumferential surface, but can also comprise a steel circumferential surface.

[0057] Preferably, during the step of providing one or more lowered areas, the web, sheet or plate material extends along the circumference of the embossing roller over an arc-shaped section of the embossing roller. By this is meant that, when viewed in the feed direction and in cross-section, the web, sheet or plate material initially contacts the embossing roller at a first point, then moves along the circumference of the embossing roller to a second point, at which the web, sheet or plate material interrupts contact with the embossing roller, wherein the arc-shaped section of the circumference is defined between the first point and the second point. The arc-shaped section preferably encompasses an angle in the range of 0° to 90°. It will be clear that this angle is defined between the radii of the embossing roller that pass through the first point and the second point. Within this range, the inventors have found that a sufficiently long contact time between the web, sheet or plate material and the embossing roller can be achieved, which can result in better formation of the one or more lowered areas.

[0058] Preferably, the transparent layer comprises recesses, and the recesses are at least partially provided by the embossing roller. It should be noted that the embossing roller can be the same as the embossing roller described above for forming the lowered areas, or can be a further embossing roller.

[0059] Preferably, in case of any of the first to third aspects, when recesses are provided in the transparent layer, an additional component can be provided in the recesses which at least partly fill the recesses. Such an additional component can for example be a colorant, a varnish, an ink, etc. For example, the technology disclosed in WO2022 / 101743 can be applied. Preferably, the step of applying the additional component is performed prior to the step of forming the lowered areas, if feasible in the context of the respective aspect and / or preferred embodiments thereof. In this way, the additional component can be avoided from unnecessarily accumulating in the lowered areas.

[0060] It is clear that the application of the additional component prior to the formation of the lowered areas has an inventive contribution in itself, and thus, the present application is according to its fourth independent aspect a method for manufacturing decorative panels, wherein the method comprises: - a step of providing a web, sheet or panel of material comprising a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern, wherein the transparent layer is provided with recesses; - a step of applying an additional component in the plurality of recesses; - a step of providing one or more lowered areas in the web, sheet or panel of material; - a step of further processing, preferably dividing, the web, sheet or panel of material into one or more of the decorative panels, wherein at least a portion of the one or more lowered areas forms a lowered edge area at one or both of the pair of opposite edges of the decorative panel; wherein, - the step of applying an additional component in the plurality of recesses is at least partly performed prior to the step of providing the lowered areas to the web, sheet or panel of material.

[0061] Preferably, the printed pattern comprises at least a pattern corresponding to at least one of the decorative panels, and preferably to a plurality of the decorative panels provided adjacent to each other on the web, sheet or panel of material. The decorative panels preferably extend in a length direction of the web, sheet or panel of material with their pair of longitudinally opposite edges, wherein the plurality of decorative panels are provided adjacent to each other at least in a transverse direction.

[0062] Preferably, the method further comprises a step of controlling the amount of additional component applied on the web, sheet or panel of material. The step of controlling can be performed by the applying device.

[0063] The application device preferably comprises a doctor blade roll and at least one application roll, and the amount of additional ingredient applied on the slab, sheet or plate-like material can be controlled by varying the distance between the doctor blade and the application roll and / or by varying the rotational speed of the doctor blade roll and / or the application roll. Preferably, during the application of the additional ingredient, the doctor blade roll and the application roll are in contact, and the circumferential surface of the application roll is pressed into by the doctor blade roll. Preferably, the circumferential surface of the application roll has a hardness between 5 Shore and 25 Shore, preferably about 15 Shore, and the circumferential surface preferably comprises polyurethane (PU). The inventors found that when the circumferential surface has this hardness, a favourable indentation on the circumferential surface can be obtained by the doctor blade roll, which allows for an optimal adjustment of the amount of additional ingredient supplied on the slab, sheet or plate-like material.

[0064] Preferably, the step of applying the additional ingredient in the plurality of recesses is at least partly performed by means of at least the application device and / or the doctor blade and / or by means of polishing and / or wiping the upper surface.

[0065] The application device preferably comprises one or more application rolls. In case the application device comprises a doctor blade roll and two or more application rolls, a preferred embodiment is as follows: the additional ingredient is fed between the doctor blade roll and a first application roll; then the first application roll is brought into contact with a second application roll; and then the additional ingredient is transferred to the second application roll. The second application roll then applies the additional ingredient to the slab, sheet or plate-like material. Using at least a second application roll allows for a better control of the entire application process.

[0066] Preferably, after the additional ingredient is applied in the plurality of recesses, at least some of the additional ingredient is removed by means of a removal roll and / or by brushing and / or grinding. For example in case the additional ingredient is a sunscreen, removing at least some of the additional ingredient will better control the final sun protection effect of the final product. Preferably, such a removal roll comprises a circumferential surface comprising ethylene propylene diene monomer (EPDM). The circumferential surface of the removal roll preferably has a hardness between 20 Shore and 80 Shore, preferably about 60 Shore. The inventors found that with a hardness in this range, the amount of additional ingredient removed from the slab, sheet or plate-like material can be optimal.

[0067] When the additional ingredient is applied by means of an application device comprising at least one application roll, at least some of the additional ingredient can also be applied on the area of the transparent layer adjacent to the recess. As mentioned above, at least some of the additional ingredient can be removed by means of a removal roll and / or by brushing and / or grinding. After the step of removal, for example by means of a removal roll, a residual film of additional ingredient can be present on the area of the transparent layer adjacent to the recess, as not all of the additional ingredient can be removed. The residual film can have a thickness of 0 micrometer to 50 micrometer, preferably less than 10 micrometer, preferably about 5 micrometer.

[0068] The residual film can have a beneficial effect on the overall appearance of the decorative panel. For example, the residual film can better mimic natural wood. However, the residual film can be undesirable.

[0069] In the specific embodiment, in the step of applying the additional component into the plurality of recesses, the additional component is aligned with the recesses by digital printing. For example, the application device can comprise a digital printer. The application device can be a digital printing engine comprising a plurality of inkjet print heads, each having a plurality of nozzles. Preferably, the digital printing engine is a single pass printer, wherein the inkjet print heads are in a stationary state and the slab, sheet or board-like material is continuously moved underneath the inkjet print heads while the additional component is printed on the slab, sheet or board-like material. By digitally applying the additional component, the presence of a residual film can be avoided. Here, the step of controlling the amount of additional component applied on the slab, sheet or board-like material is preferably embedded in the digital data controlling the inkjet print heads. For example, in addition to having specific nozzles fire or not, the data resolution, the size of the ink droplets fired by specific nozzles of the inkjet head can be varied. Preferably, the inkjet print heads are of the “drop on demand” type.

[0070] The step of providing one or more lowered areas can be performed according to any of the preferred embodiments of the first to third aspects of the application, for example according to any of the first to third possibilities mentioned in the second aspect of the application. Preferably, the step of providing one or more lowered areas is performed by any of the following three possible embodiments.

[0071] According to a first possible embodiment, the step of providing one or more lowered areas in the slab, sheet or board-like material is performed by means of a pressing operation. The pressing operation can be performed by a discontinuous or continuous cold press or a discontinuous or continuous hot press.

[0072] The press preferably comprises a die portion, wherein the die portion has an overall surface comprising at least one protrusion, and wherein the protrusion contacts the slab, sheet or board-like material during the pressing operation, and characterized in that the protrusion corresponds to the position of at least one of the plurality of lowered areas. More preferably, the length of the one or more protrusions is greater than or equal to the length and / or width of the slab, sheet or board-like material.

[0073] Preferably, the protrusion extends from the adjacent portion of the overall surface of the die portion by a distance greater than the depth of the lowered area. The inventors found that in the context of the present application, a large part of the pressed material tends to spring back by pressing into the thermoplastic material. By making a deeper impression in the material than the desired depth of the lowered edge area in the final product, the desired final result can be obtained.

[0074] It should be noted that this first possible implementation can also exhibit the features and / or preferred features of the second possibility mentioned in the second aspect of the application.

[0075] According to a second possible implementation, the step of providing one or more lowered areas is performed at least partly by means of a press roll.

[0076] Preferably, the counter pressure roll is used together with the press roll, which counter pressure roll preferably has a rubber or synthetic rubber or steel circumferential surface.

[0077] Preferably, the circumference of the press roll comprises at least one protrusion corresponding to the position of at least one of the lowered areas.

[0078] The protrusion preferably extends from an adjacent part of the circumference, the height of the protrusion being greater than the depth of the lowered area. The inventors have found that by pressing into the thermoplastic material, a large part of the pressed material tends to spring back. By making a deeper press in the material than the desired depth of the lowered edge area in the final product, the desired final result can be obtained.

[0079] It should be noted that this second possible implementation can also exhibit the features and / or preferred features of the first possibility mentioned in the second aspect of the application.

[0080] According to a third possible implementation, the step of providing one or more lowered areas in the web, sheet or plate-like material is performed at least by milling out the lowered areas in the web, sheet or plate-like material.

[0081] Preferably, the method further comprises the step of applying a primer and / or a top coat on top of the additional ingredient. Such primer and / or top coat can serve to protect the surface and to increase the scratch resistance of the decorative panel obtained according to the method.

[0082] Preferably, the method further comprises the step of curing the primer and / or the top coat by means of radiation and / or heat.

[0083] Preferably, the additional ingredient comprises a varnish, a paint, etc. or a powder, and preferably, the additional ingredient comprises a photoinitiator.

[0084] Preferably, the additional ingredient is cured by means of UV radiation. UV curing can make the manufacturing process flow, wherein, for example, the curing stage can be chosen based on subsequent processing steps.

[0085] According to a further embodiment of the third aspect of the application, the additional ingredient is at least partially cured by means of radiation, preferably before the step of providing one or more lowered areas to the slab, sheet or board-like material. The inventors found that at least partially curing the additional ingredient can result in an adhesion in the lowered areas that is sufficient to avoid contamination of the equipment in subsequent operations. Preferably, the additional ingredient is only partially cured before the step of providing one or more lowered areas. Curing the additional ingredient completely is not desirable, because it shows hardly any deformability and can cause cracks in the completely cured additional ingredient applied on the surface of the slab, sheet or board-like material during the step of providing one or more lowered areas. This can result in an undesirable aesthetic effect on the decorative panel. Preferably, the slab, sheet or board-like material is heated during or at least partially separately from the at least partial curing. Such heating can improve the plastic deformation capability of the material, so that cracks can be avoided.

[0086] According to a further embodiment of the third aspect of the application, the method comprises the step of partially curing the additional ingredient by means of heat. In this case, the additional ingredient comprises a thermal initiator. The partial curing of the additional ingredient is at least partially performed before the step of providing one or more lowered areas to the slab, sheet or board-like material, and the partially cured additional ingredient is completely cured after the step of providing one or more lowered areas to the slab, sheet or board-like material. The inventors found that at least partially curing the additional ingredient can result in an adhesion in the lowered areas that is sufficient to avoid contamination of the equipment in subsequent operations. Curing the additional ingredient completely is not desirable, because it shows hardly any deformability and can cause cracks in the completely cured additional ingredient applied on the surface of the slab, sheet or board-like material during the step of providing one or more lowered areas. This can result in an undesirable aesthetic effect on the decorative panel.

[0087] Preferably, the step of at least partially curing the additional ingredient by means of heat is achieved by a pressing and / or embossing operation.

[0088] Generally, in the context of the present application, the additional ingredient is applied in the recess of the transparent layer without excluding the case that the slab, sheet or board-like material already is provided with lowered areas. It can prove advantageous to apply the additional ingredient after the lowered areas have been provided to prevent cracks as mentioned in the embodiments described above. In this case, preferably additional measures are taken to limit or prevent accumulation of the additional ingredient in the lowered areas. Limitation of such accumulation is of technical importance, because it can make the manufacturing method more efficient and with fewer steps.

[0089] The present application is therefore according to its fifth independent aspect a method for manufacturing a decorative panel, wherein the method comprises: - a step of providing a slab, sheet or board material comprising a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern, wherein the transparent layer is provided with recesses; - a step of providing one or more lowered areas in the slab, sheet or board material; - a step of applying an additional component in the recesses; - a step of further processing, preferably dividing, the slab, sheet or board material into one or more of the decorative panels, wherein at least a portion of the one or more lowered areas forms a lowered edge area at one or both of a pair of opposite edges of the decorative panel; wherein, - after the step of providing the lowered areas to the slab, sheet or board material, at least partly performing the step of applying an additional component in the recesses, wherein a device is used to apply the additional component, wherein the device applies the additional component in an equal or less amount in the lowered areas.

[0090] When the additional component is applied on a larger slab, sheet or board material which has been pre-provided with lowered areas, these lowered areas tend to be filled with additional component, which further complicates the operation of dividing into panels and increases the risk of the edge areas not presenting the desired dimensions. A device configured to apply the additional component in an equal or less amount in the lowered areas can also avoid the use of a specifically adapted removal process to level or remove the additional component in the lowered areas.

[0091] It is clear that the device mentioned in the fifth independent aspect is preferably able to apply the additional component in an equal or less amount at the lowered areas themselves, i.e. without the need for a mechanism to remove the excess applied additional component after the device has applied the additional component.

[0092] The device can be practiced in many different ways, a non-exhaustive list of which is listed below.

[0093] According to a preferred embodiment, the device comprises at least one application roller, wherein the outer surface of the application roller comprises at least one protrusion. The application roller preferably contacts or is in close proximity to the slab, sheet or plate-like material to which the additional ingredient is to be provided. In this case, the application roller itself directly delivers the additional ingredient to the slab, sheet or plate-like material by means of its active coating surface. According to an alternative, the application roller can indirectly deliver the additional ingredient, for example by means of an intermediate piece of a transfer roller. Preferably, the one or more protrusions extend outwardly from the adjacent portion of the outer surface by a distance of between 0 mm and 1 mm. The position of the at least one protrusion preferably corresponds at least to the position of one of the lowered areas and / or, when a plurality of protrusions are comprised on the surface, to the positions of a plurality of lowered areas and / or to the positions of other areas where it is desired to apply the additional ingredient to an equal or lesser extent or where it is not desired to apply the additional ingredient.

[0094] Preferably, the device comprises a doctor blade roller which is positioned in close proximity to or in contact with the application roller. The application roller can be used to control the thickness of the additional ingredient. The doctor blade roller is preferably rotated in a different rotational direction to create a shearing action which removes excess additional ingredient from the application roller. The additional ingredient is provided to the application roller at the nip between the doctor blade roller and the application roller. Preferably, the hardness of the doctor blade roller exceeds the hardness of the application roller, so that when the doctor blade roller and the application roller are in contact and both are rotating, the application is pressed out of the indentations. Due to the protrusions on the application roller, the nip is locally narrowed at the positions where the protrusions are in contact with the doctor blade roller, which results in less or no additional ingredient being provided on the outer surface of the protrusions. The positions of the protrusions correspond to the positions of the lowered areas and / or of areas where it is desired to apply the additional ingredient to a lesser or equal extent or where it is not desired to apply the additional ingredient, so that no or less additional ingredient can be provided to the lowered areas and these areas.

[0095] Preferably, the protrusions comprise a side portion which has a slope with respect to the adjacent portion of the circumference of the outer surface of the application roller, wherein the slope is between 90° and 180°, and wherein the side portion preferably extends at least 50 percent of the height of the protrusion. In this process, the inventors have found that it is possible to achieve a reduction in the build-up of additional ingredient between the areas adjacent to the protrusions and the protrusions.

[0096] Preferably, the hardness of the one or more protrusions is the same as or preferably harder than the hardness of the adjacent portion of the circumference of the outer surface of the roller.

[0097] According to a preferred embodiment, the device comprises a plurality of application rollers rotating around the same or parallel axes, wherein the application rollers preferably all comprise an active coating surface, and wherein the application rollers and / or their respective active coating surfaces are separated by a distance which is preferably at least greater than or equal to the width of one of the one or more lowered regions. Due to this distance, the additional component will be applied in a less manner, or in fact not at all in this lowered region. Preferably, the application rollers are each individually fed with the additional component, preferably such that the additional component fed to a first roller cannot come into contact with the additional component fed to a second roller, especially before being applied to the slab, sheet or board-like material. In this case, the risk of accumulation of the additional component in the lowered region can be further limited. Furthermore, different additional components can be applied by two or more application rollers. The difference can for example comprise a tonal difference.

[0098] Preferably, the distance between the application rollers and / or the active coating surfaces corresponds at least to the lowered region and / or the region in which the additional component is not desired to be applied, and / or at least to the technical region which is at least partially removed during a further processing step. Preferably, the distance between the application rollers and / or the active coating surfaces corresponds or substantially corresponds to the distance between the overall upper surfaces of two adjacent decorative panels comprised in the slab, sheet or board-like material, i.e. is equal to twice the width of the drop-off edge region of the final decorative panel to be obtained plus the width of the technical region.

[0099] In a preferred embodiment, the nip between the doctor blade roller and the application roller can be divided into a plurality of nips by providing at least one removable portion between the doctor blade roller and the application roller. Preferably, the at least one removable portion directly contacts the rollers. Preferably, the divided nips are each fed with the additional component. Preferably, the placement of the at least one removable portion corresponds at least to the position of one of the plurality of lowered regions, and / or, when a plurality of removable portions are provided between the doctor blade roller and the application roller, to the positions of the plurality of lowered regions and / or to other regions in which it is desired to apply the additional component in an equal or less manner or not at all.

[0100] According to a preferred embodiment, the device is a digital application device, such as an inkjet printer or a valvejet printer. With this device, the application of the additional component can be controlled in such a way that the additional component is applied in an equal or less manner in the lowered region. The control of the amount of application or the position of application can be predetermined by means of digital data input to the printer, or can be based on an online detection of the lowered region, directly or indirectly.

[0101] It is in itself interesting to use digital application techniques to provide the additional ingredient, whether or not a reduced area is present in the slab, sheet or board material. Therefore, the present invention is according to its sixth independent aspect a method for manufacturing a decorative panel, wherein the method comprises: - a step of providing a slab, sheet or board material comprising a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern, wherein the transparent layer is provided with recesses; - a step of applying an additional ingredient in the recesses; - a step of further processing, preferably segmenting, the slab, sheet or board material into one or more of the decorative panels; wherein, - the step of applying an additional ingredient in the recesses is at least partly performed by digitally applying the additional ingredient.

[0102] Preferably, the additional ingredient is at least partly applied by using a digital printing engine comprising a plurality of inkjet print heads and / or valve-jet print heads, each print head preferably having a plurality of nozzles. Preferably, the digital printing engine is a single pass printer, wherein the print heads are in a stationary state and the slab, sheet or board material is continuously moved underneath the print heads while the additional ingredient is printed on the slab, sheet or board material. By digitally applying the additional ingredient, it is possible to avoid the presence of a residual film on the surface portions between the recesses. Here, the amount of additional ingredient applied on the slab, sheet or board material can be controlled and this step is preferably embedded in the digital data controlling the print heads. For example, in addition to having specific nozzles fire or not, it is possible to vary the data resolution, the size of the ink droplets fired by specific nozzles of the print heads. Alternatively or additionally, the amount of additional ingredient to be applied can be controlled by online direct or indirect detection of the recesses and / or other available features such as reduced areas. Preferably, the print heads are “drop-on-demand” type inkjet print heads.

[0103] Preferably, the printed pattern is at least partly provided in a similar way as the additional ingredient. For example, the printed pattern can be provided by digitally applying ink on the substrate, preferably through the intermediary of one or more primer layers. Preferably, a UV (ultra-violet) curable ink is applied.

[0104] Preferably, the recesses are at least partly provided by a digital method such as digital stamping, but it is also possible to provide the recesses by an analog method such as already described in one of the previous independent aspects, for example by means of a stamping roller and / or by means of a pressing operation. Preferably, the recesses are aligned with the printed pattern. In case a digital stamping technique is applied to provide the recesses, preferably the technique comprises: - applying a curable lacquer, preferably a radiation curable (e.g. UV curable) lacquer, in liquid form. The liquid application can be performed by means of one or more roll coaters; - digitally applying a texturizing fluid in the curable lacquer which has not yet cured or which has not yet fully cured, wherein the texturizing fluid locally displaces, replaces or changes the curable lacquer, wherein in case of a change this involves a change in curability; - curing the curable lacquer; - optionally removing the texturizing fluid, e.g. in case the texturizing fluid replaces or changes the curable lacquer.

[0105] Preferably, the chemical composition of the transparent layer is similar to the additional ingredient, preferably both the transparent layer and the additional ingredient comprise an acrylic ingredient. The inventors found that the inclusion of an acrylic ingredient in both the additional ingredient and the transparent layer results in a better adhesion between the additional ingredient and the transparent layer. This is especially the case when using UV-cured inks to provide the printed pattern, as such inks can also comprise an acrylic ingredient.

[0106] It will be understood that the present application also relates to a decorative panel which can be obtained by one of the various manufacturing methods disclosed in any of the foregoing independent aspects and / or preferred embodiments thereof. In particular, the decorative panel has reduced edge regions or lowered edge regions which are substantially free of additional ingredient, whereas the additional ingredient is present in the depressions of the overall surface, which can provide a significant advancement in mimicking natural wood and other decorative types, regardless of their manner of manufacture. The present application is thus according to its seventh independent aspect a decorative panel having a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern, wherein the transparent layer is provided with depressions, and wherein the panel comprises a lowered edge region at one or both of a pair of opposite edges, wherein the plurality of depressions are provided with additional ingredient, whereas at least part of the lowered edge region is substantially free of additional ingredient or is only covered by a residual film of additional ingredient.

[0107] Some preferred features are listed below, which can be combined with any of the above seven independent aspects and / or preferred embodiments thereof.

[0108] In case the decorative panel comprises a lowered edge region at one or both of a pair of opposite edges, preferably the printed pattern continuously extends from the overall surface of the decorative panel towards and over at least part of the lowered edge region.

[0109] In case the additional ingredient is applied, preferably the additional ingredient is present mainly in the recesses and preferably not in the area between the recesses. Alternatively, a residual film can be present on the area between the recesses. Further, the lowered edge area can comprise local recesses, wherein the plurality of local recesses are provided with the additional ingredient.

[0110] Preferably, the additional ingredient is an opacifying ingredient and the additional ingredient preferably improves the aesthetics of the decorative panel. This is especially the case when the additional ingredient is applied on the thermoplastic material, as the additional ingredient weakens the plastic appearance of the decorative panel, making it possible to better imitate e.g. wood.

[0111] Another possibility is that the additional ingredient is a colorant, such as a dye or ink.

[0112] Preferably, the thickness of the residual film of the additional ingredient, when present, is between 0 and 50 micrometer, preferably less than 10 micrometer, preferably about 5 micrometer.

[0113] Preferably, the substrate comprises at least one material from the list consisting of: polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polyurethane (PU), polylactic acid (PLA), polyethylene terephthalate (PET), glycol-modified polyethylene terephthalate (PETG), medium density fiberboard (MDF), high density fiberboard (HDF), and more preferably the substrate comprises a thermoplastic material, preferably PVC. It is also preferred that the substrate comprises 5 phr or less of plasticizer or is plasticizer-free. For example, a rigid PVC can be applied, i.e. a PVC that is free of or contains less than 5 phr plasticizer. The PVC can be foamed or unfoamed. In case of a foam material, preferably the density is reduced due to foaming by at least 5% compared to the same composition in unfoamed state, for example by 10% or more, or even 20% or more.

[0114] Preferably, the substrate comprises a filler material, such as calcium carbonate (CaC03) and / or wood fibers and / or sand and / or talc and / or limestone, etc. The substrate can for example be a filled plastic composite, such as a filled PVC.

[0115] Preferably, the recesses each have a maximum depth in the range between 0 and 350 micrometer. The inventors found that in this depth range the best visual effect is obtained due to the application of the additional ingredient. Especially for recesses with a depth of 100 pm or more, it is possible to apply the additional ingredient sufficiently therein to create a significant effect (e.g. a color effect), without the need to completely fill the recess, thereby also obtaining a residual haptic effect.

[0116] Preferably, the printed pattern is provided on a carrier sheet, wherein the carrier sheet preferably comprises a thermoplastic material and / or a paper-based material, which is then laminated and / or glued to the substrate. Another possibility is to print the printed pattern directly on the substrate in an analog or digital manner.

[0117] Preferably, the transparent layer comprises a thermoplastic and / or a paper-based material, and preferably a varnish and / or a coating is applied on the transparent layer. The transparent layer can also comprise a varnish and / or a coating.

[0118] The decorative panel preferably comprises a coupling portion on at least one pair of opposite edges, such that a mechanical locking between two such decorative panels can be achieved, wherein in the coupled state a locking in a direction perpendicular to the plane of the coupled panels and in a direction within the plane and perpendicular to the coupling edges can be obtained. Preferably, the coupling portion is provided in one piece with the panel-like material, i.e. without inserts at the respective edges. Preferably, the coupling portion is realized substantially as a tongue-and-groove connection, wherein the tongue and the groove are provided with mechanical locking portions to prevent the tongue and the groove from being separated from each other.

[0119] Possibly, the base comprises a local stress zone. Such a local stress zone can possibly result from the step of providing a lowering area into the blank, sheet or panel-like material, in particular when the lowering area is obtained by means of a pressing operation by means of e.g. a platen press or a discontinuous press. Preferably, the local stress zone comprises at least a portion on one or both of the edges of the pair of opposite edges. Preferably, the relevant edge is a shaped edge, e.g. comprising a coupling portion. By means of the shaped edge, the remaining material of the local stress zone can be minimized. Preferably, the remaining material can be provided at at least one area of the coupling portion which is not critical for the overall strength of the mechanical locking system between the decorative panels, and / or the material or the remaining material of the local stress zone is located at a distance from the weakest portion of the coupling portion.

[0120] From the above it will be clear that it can be important to well manage the position of the local stress zone in the substrate for maintaining sufficient locking strength in the coupled part. Therefore, the invention according to its eighth independent aspect is a decorative panel having a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern, wherein the substrate is a filled synthetic material and the panel comprises at one or both of a pair of opposite edges a lowered edge region, wherein the pair of opposite edges are provided with mechanical coupling means allowing two such panels to lock to each other at the respective edges in a vertical direction perpendicular to the plane of the coupled panels and in a horizontal direction perpendicular to the edges and in the plane of the coupled panels, wherein the coupling means are essentially formed as a tongue comprising a portion protruding from the respective edge and a recess bounded by an upper lip and a lower lip, wherein the substrate comprises at one or more of the edges a local stress zone, wherein the stress zone is present in the protruding portion of the tongue and / or in the lower lip of the recess and / or in the upper lip of the recess. By having the local stress zone in this position, the remaining material can be minimized and the influence on the locking strength can be limited accordingly.

[0121] Preferably, the local stress zone is mainly present in the protruding portion of the tongue and / or in the lower lip of the recess and / or in the upper lip of the recess.

[0122] Preferably, the local stress zone affects as little material as possible and / or the local stress zone is at a horizontal distance from the thinnest section of the lower lip of the recess between 0.1 mm and 1 mm.

[0123] Preferably, the substrate comprising a filled synthetic material means that the substrate comprises one, two or more sub-layers, wherein at least one sub-layer and preferably all sub-layers comprise a filled synthetic material. The filled synthetic material preferably comprises a thermoplastic material and a filler material, such as an organic or inorganic filler material, and optionally a plasticizer. The organic filler can comprise wood particles, such as wood fibers or wood chips. The inorganic filler can comprise, for example, chalk, talc or limestone. The weight ratio between the thermoplastic material and the filler can be between 90:10 and 10:90, preferably 80:20 and 20:80. For example, the panel can comprise a filled synthetic material composite, wherein

[0124] - thermoplastic material excess means that the weight ratio between the thermoplastic material and the filler is higher than 50:50; - filler excess means that the weight ratio between the thermoplastic material and the filler is lower than 50:50. The sub-layers can be foamed or can be non-foamed.

[0125] It should be noted that in case the filled synthetic material comprises a thermoplastic material, such as PVC, the local stress zone can appear as a whitish area.

[0126] It is clear that the decorative panel of the eighth aspect can comprise a lowered edge region at one or both of the pair of opposite edges. The local stress zone can be obtained by providing the lowered edge region. Therein, the method according to any one of the aspects and / or preferred embodiments disclosed above can be applied, and the decorative panel of the eighth aspect can exhibit the corresponding features associated with these aspects and preferred embodiments.

[0127] The inventors have further found that an adapted design of the press tool used to form the lowered region can further limit the occurrence and / or severity of the local stress zone. The present invention is therefore according to its ninth independent aspect a method for manufacturing a decorative panel, wherein the method at least comprises: - a step of providing a blank, sheet or plate of material comprising a substrate and a top layer applied on the substrate, the top layer comprising at least a printed pattern and a transparent layer applied on the printed pattern; - a step of providing one or more lowered regions in the blank, sheet or plate of material; - a step of further processing, preferably at least dividing, the blank, sheet or plate of material into one or more of the plurality of decorative panels, wherein at least a part of the one or more lowered regions forms a lowered edge region at one or both of the pair of opposite edges of the decorative panel; characterized in that the step of providing one or more lowered regions in the blank, sheet or plate of material at least comprises a preferably non-continuous pressing operation by means of a press having a press tool, wherein the press tool comprises at least a first protrusion on the part of the tool surface that contacts the blank, sheet or plate of material during the pressing operation, wherein the first protrusion at least corresponds to the position of at least one of the plurality of lowered regions, wherein the press tool comprises at least a second protrusion extending substantially parallel to the first protrusion, wherein the second protrusion contacts the blank, sheet or plate of material during the pressing operation and corresponds to a part of the blank, sheet or plate of material that is removed in the finishing step.

[0128] Preferably, the second protrusion deforms the substrate during the pressing operation. More preferably, the second protrusion forms an additional lowered area in this portion of the web, sheet or board material, which additional lowered area is removed in the further processing step. Preferably, the depth and / or void volume of the additional lowered area is equal or substantially equal to the depth and / or void volume of the lowered area formed by the first protrusion, respectively. Herein, the depth and volume are defined with the level defined by the overall upper surface of the web, sheet or board material as a boundary. Alternatively, the depth and / or void volume of the additional lowered area is smaller than the depth and / or void volume of the lowered area formed by the first protrusion, but preferably at least 25% or at least 50% of the depth or void volume of the lowered area formed by the first protrusion, respectively. It is not excluded that the depth and / or void volume of the additional lowered area is larger than the depth and / or void volume of the lowered area formed by the first protrusion, but preferably not more than 125% of the depth, void volume of the lowered area formed by the first protrusion, respectively. According to a variant, a plurality of protrusions or second protrusions or segments thereof can be applied to form a plurality of additional lowered areas in the side portion, wherein the sum of the void volumes of the plurality of additional lowered areas can meet the above-mentioned preferred depth and / or void volume dimensions.

[0129] The inventors found that the second protrusion, especially when deforming the substrate, can form a counter pressure against the shearing forces applied by the first protrusion, such that the local stress zone at the location of the first protrusion is less severe. The local stress zone occurring at the location of the second protrusion can still be more severe. Preferably, the location of the second protrusion is such that it is located directly above the material of the web, sheet and board material to be completely removed. For example, the location of the second protrusion can be located directly above a material of the web, sheet and board material that is far away from the outermost point or farthest point of the shaped edge of the decorative panel to be formed in the further processing step. In case the shaped edge of the decorative panel comprises a coupling portion of a basic shape with a tongue and groove connection, preferably with a locking portion preventing the tongue and groove from separating, such outermost point of the shaped edge can for example be formed by the material of the lip defining the groove, preferably the groove lower lip, or by the material of the tongue end. In this case, the influence of the more severe local stress zone at the second protrusion can be minimized. The local stress zone or parts thereof generated by means of the first protrusion and / or the second protrusion can be located in the decorative panel, preferably within the coupling portion as described in the context of the eighth aspect of the invention.

[0130] Preferably, the slab, sheet or board material comprises material for a plurality of decorative panels, wherein at least one decorative panel of the plurality of decorative panels is spaced from an edge of the slab, sheet or board material removed in a further processing step only by a side portion of the slab, sheet or board material, wherein the second protrusion corresponds to a portion within the side portion, and wherein the at least one lowered area corresponds to the first protrusion forming a proximal delimitation of the side portion. In particular, for a decorative panel adjacent to such a side portion, it is important to use the second protrusion, since there is hardly any other resistance than by means of the second protrusion that can minimize or avoid shearing at the first protrusion. The first protrusion providing a lowered area at the center of the slab, sheet or board material is preferably adjacent to a first protrusion providing a lowered area to an adjacent panel. In this case, shearing can be minimized by having the first protrusion responsible for providing an adjacent lowered area of an adjacent decorative panel in the slab, sheet or board material adjacent.

[0131] In a ninth aspect, "extending substantially in parallel" mainly means that the second protrusion is preferably entirely parallel to the first protrusion. However, there are multiple possibilities for the second protrusion to still be able to exert a counter pressure in case of deviating from such an entire parallelism. The following exemplary possibilities are also considered to fulfill the "extending substantially in parallel" feature. According to a first example, the second protrusion can extend substantially linearly but at a limited angle to the first protrusion, for example at an angle of 10° or less, or 5° or less, or 2° or less. According to a second example, the second protrusion can extend in a non-linear manner. In this case, the second protrusion preferably defines a least-squares line extending substantially in parallel to the first protrusion, i.e. entirely parallel or with a deviation from parallelism having a limited angle as defined above. According to a third example, the second protrusion can be formed by linear or non-linear segments, whether overlapping or not, wherein these segments do not necessarily have equal extensions or shapes. Also in this case, the second protrusion preferably defines a least-squares line extending substantially in parallel to the first protrusion, i.e. entirely parallel or with a deviation from parallelism having a limited angle as defined above. It should be noted that the second protrusion extends with a certain width extension in cross-section. However, the least-squares line defined by the second protrusion can be defined in several consistent ways, for example by means of the highest point in each cross-section of the second protrusion, wherein in case there are multiple highest points in a cross-section, the one closest to the first protrusion is considered.

[0132] The first and second protrusions have a first and second position of maximum height in cross-section, respectively. Preferably, the shortest distance between the first and second position of maximum height measured in cross-section and transversely to the first and second protrusions is one or more of the following: - 5 times or less the thickness of the slab, sheet or plate material, 2 times or less the thickness of the slab, sheet or plate material; - 7 times or less or 5 times or less the maximum height of the first protrusion; - less than 20 mm, less than 10 mm, or less than 5 mm.

[0133] Alternatively, preferably, the lowered area formed by the first protrusion and the additional lowered area formed by the second protrusion each have a first and second position of a maximum depth in cross-section. Preferably, the shortest distance between the first and second position of the maximum depth, when measured in cross-section and transversely to the lowered area and the additional lowered area, is one or more of: - 5 times or less the thickness of the slab, sheet or plate material, 2 times or less the thickness of the slab, sheet or plate material; - 7 times or less or 5 times or less the maximum depth of the lowered area provided by the first protrusion; - less than 20 mm, less than 10 mm, or less than 5 mm.

[0134] Preferably, the first position is at a depth of 0.6 mm to 1.5 mm, or at a depth of 0.75 mm to 1.25 mm. The depth of the second position can be equal to or preferably slightly higher than e.g. between 0.9 and 1.1 times the depth of the first position. The inventors point out that a higher second protrusion can well and reliably limit the severity of the stress zone at the position of the lowered area formed by the first protrusion.

[0135] When considering the distance between the first and second position, the shortest or minimum distance between these positions can be considered, e.g. when these positions are relatively far apart as seen in cross-section.

[0136] The relative proximity of the first and second protrusion can result in an optimal counter pressure by the second protrusion on the shear forces exerted by the first protrusion.

[0137] It is noted that the distance between the first and second position, whether it is the maximum height of the respective protrusion or the maximum depth of the respective lowered area, can be different at opposite side portions of the slab, sheet or plate material. For example, in case the decorative panel has a tongue and groove connection, e.g. with a locking portion, the distance can be larger at the side portion adjacent to the final panel edge having a coupling portion with a groove shape than at the side portion adjacent to the final panel edge having a coupling portion with a tongue shape. This can especially be the case when the groove is bounded by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip. The minimum distance can be within 35% to 70% of the larger distance.

[0138] The distance between the first position and the second position is preferably such that the second position is distanced from the profile of the coupling part to be formed on the respective edge.

[0139] Preferably, the second protrusion extends at least uninterruptedly along the entire length of the first protrusion, or at least along a length corresponding to the entire length or substantially the entire length or at least 80% of the entire length of the lower edge formed by the lowered area formed by the first protrusion. Alternatively, the second protrusion can comprise one or more interruptions arranged along the length of the first protrusion or along a length corresponding to the entire length of the lowered edge area formed by the lowered area formed by the first protrusion. In this case, preferably one or more of the following measures are taken to effectively minimize the severity of the stress zone: - a measure that any interruption in the second protrusion is less than 20%, or less than 10% or less than 5% of the entire length of the lowered edge area formed by the lowered area formed by the first protrusion; - a measure that any interruption in the second protrusion is less than 5 times the thickness of the slab, sheet or plate-like material; - a measure that the sum of the lengths of all interruptions in the second protrusion is less than 25% of the entire length of the lowered edge area formed by the lowered area formed by the first protrusion; - a measure that the press mold comprises at least a third protrusion extending substantially parallel to the interruptions in the second protrusion.

[0140] Preferably, the length of the interruptions is considered in a direction parallel to the first protrusion.

[0141] Preferably, at least a second protrusion is provided which extends substantially parallel to the at least one outermost first protrusion of the pressing mould. Such second protrusion then preferably provides an additional lowered area in a first side portion of the board blank, sheet or plate-like material, i.e. in a portion forming a first edge of the board blank, sheet or plate-like material, wherein the first side portion is the only material separating the lowered area formed by the first protrusion from the first edge of the board blank, sheet or plate-like material. In case of a decor panel which extends longitudinally and is oblong, preferably the first protrusion is arranged for forming a lowered area providing a lowered edge area at one of the pair of longitudinal edges of the panel to be finally obtained. Obviously, the first side portion is intended to be removed in a further processing step. Preferably, also a further second protrusion is provided for forming a further additional lowered area at a second side portion of the board blank, sheet or plate-like material, i.e. in a portion forming a second edge of the board blank opposite to the first edge, wherein the second portion is thus opposite to the first side portion. The further second protrusion then preferably extends substantially parallel to a further first protrusion which provides a lowered area for forming a lowered edge area at one of the pair of longitudinal edges of the further panel to be finally obtained, wherein the material of the panel is adjacent to the second side portion in the board blank, sheet or plate-like material. One or more second protrusions can similarly be used for forming additional lowered areas at one or more of the lateral side portions of the board blank, sheet or plate-like material, i.e. in one or more portions forming a lateral edge of the board blank, sheet or plate-like material, wherein these second protrusions then extend substantially parallel to the first protrusions which provide a lowered area for forming a lowered edge area at one of the pair of short edges of the further decor panel to be finally obtained.

[0142] It will be appreciated that the method of the ninth aspect can be combined with the method of any of the previous aspects and / or preferred embodiments thereof.

[0143] The present application is also a pressing mould for use in the method of the ninth aspect of the present application, characterized in that the pressing mould comprises a first protrusion and a second protrusion. More specifically, the pressing mould comprises a plurality of adjacent surface sections, wherein each surface section corresponds to a decor panel, and wherein at least one surface section comprises a first protrusion, wherein the first protrusion is spaced apart from an edge of the pressing mould only by a side portion of the pressing mould which does not have a surface section corresponding to a decor panel, or in other words, the first protrusion forms part of an outermost surface section or distal surface section, and wherein the side portion of the pressing mould comprises a second protrusion which extends substantially parallel to the first protrusion.

[0144] Preferably, the first protrusion and the second protrusion have the same height, or wherein the height difference between the first protrusion and the second protrusion is less than 15% of the height of the higher of the first protrusion and the second protrusion.

[0145] The cross-section of the first protrusion and the second protrusion can be the same, or substantially the same. Preferably, however, the first protrusion and the second protrusion have a shape that is different from each other. For example, the second protrusion can be substantially U-shaped, while the first protrusion is substantially V-shaped, and / or the first protrusion and the second protrusion can have a comparable height, e.g. the height of the second protrusion is between 0.9 and 1.1 times the height of the first protrusion, but the width observed in the cross-section of the first protrusion and the second protrusion at half the respective depth differ significantly from each other, e.g. the width of the second protrusion at half the depth is between 0.25 and 0.85 times the width of the first protrusion at half the depth. For example, the second protrusion can be substantially U-shaped, while the first protrusion is substantially V-shaped.

[0146] It is further noted that with respect to any of the independent aspects above and / or preferred embodiments thereof, the decorative panel can comprise an additional layer positioned between the substrate and the top layer. The additional layer can comprise a foamed thermoplastic material. In case the substrate comprises PVC, the foamed thermoplastic material can be foamed PVC and preferably comprises a higher amount of plasticizer than the amount of plasticizer present in the substrate. Preferably, the additional layer can be laminated or glued on top of the substrate, or the additional layer can be co-extruded with the substrate when the substrate is extruded. The inventors have found that the additional layer facilitates the step of providing a lowered area, in particular when this step is performed by means of a pressing or embossing operation. It is further noted that preferably, the lowered area is mainly provided in the additional layer, and the substrate is only partially deformed or not deformed at all by the pressing or embossing operation. This way the presence of local stress zones in the substrate is minimized. In case the lowered area is provided by means of a pressing operation, preferably a non-continuous press is used, which is heated to a temperature in the range of 100-150 °C. Preferably, the slab, sheet or board material has a temperature lower than 65 °C. The inventors have found that with these preferred process temperatures, the spring back of the additional layer is minimized. BRIEF DESCRIPTION OF DRAWINGS

[0147] In order to better illustrate the characteristics of the application, in the following some preferred embodiments are described, by way of example and without any limiting nature, with reference to the attached drawings, in which: Figure 1 is a perspective view representing a decorative panel obtained by means of a method according to the present application; Figure 2 is a cross-sectional view taken along the line II-II in Figure 1 Figure 1 ; Figure 3 illustrates some steps in the method according to the first aspect of the application; and Figure 4 and Figure 5 are views in larger scale of the areas indicated with F8 in Figure 3 are cross-sectional views taken along the lines IV-IV and V-V in Figure 6 illustrate some of the steps in the method according to the first aspect of the application, in addition to other steps; Figure 7 illustrate some of the steps in the method according to the second aspect of the application, in addition to other steps; Figure 8 are views in larger scale of the areas indicated with F10 in Figure 7 are views in larger scale of the areas indicated with F8 in Figure 9 are cross-sectional views taken along the lines IX-IX in Figure 7 are views in larger scale of the areas indicated with F11 in Figure 10 are views in larger scale of the areas indicated with F12 in Figure 7 are views in larger scale of the areas indicated with F13 in Figure 11 are views in larger scale of the areas indicated with F14 in Figure 9 are views in larger scale of the areas indicated with F11 in Figure 12 are views in larger scale of the areas indicated with F12 in Figure 7 are views in larger scale of the areas indicated with F13 in Figure 13 are views in larger scale of the areas indicated with F14 in Figure 7 are views in larger scale of the areas indicated with F13 in Figure 14 are views in larger scale of the areas indicated with F14 in Figure 11 are views in larger scale of the areas indicated with F14 in Figure 15 are cross-sectional views taken along the lines XV-XV in Figure 13 are views in larger scale of the areas indicated with F16 in Figure 16 are views in larger scale of the areas indicated with F16 in Figure 13 are views in larger scale of the areas indicated with F16 in Figure 17 the variant is represented in a view similar to the view of Figure 8 Figure 18 is a top view of a pressing mould for use in the method according to the ninth aspect of the application; Figure 19 is a cross-sectional view according to the line XIX-XIX indicated in Figure 18 and Figure 20 and Figure 21 ​Variations are shown in the same view; and Figures 22 to 25 In Figure 19 The view on the area designated by F22 in the middle represents a variation. DETAILED DESCRIPTION

[0148] Figure 1 A decorative panel 1, more specifically a floor panel, is shown. The decorative panel 1 is rectangular and oblong and is provided with a pair of longitudinally opposite edges 2-3 and a pair of short opposite edges 4-5.

[0149] Figure 2 It is shown that the floor panel 1 is provided with a drop edge area 6 at least at at least two edges 2-3 of the pair of longitudinally opposite edges. Preferably, as Figure 1 is shown, also two edges 4-5 of the pair of short opposite edges are provided with a drop edge area 6. The horizontal distance H over which the drop edge area 6 extends at the pair of short opposite edges 4-5 can be shorter than the horizontal distance over which the drop edge area 6 extends at the pair of long opposite edges 2-3.

[0150] Figure 2 It is further shown clearly that the decorative panel 1 comprises a substrate 7 and a printed pattern 8 and a transparent layer 9 provided on the substrate. The printed pattern 8 and the transparent layer 9 extend continuously from the overall upper surface 10 of the decorative panel 1 towards and over the drop edge area 6. Preferably, the printed pattern 8 extends continuously to the respective upper edge 11.

[0151] In Figure 2 the example, the printed pattern 8 is provided on a thermoplastic film 12.

[0152] The substrate 7 is preferably a filled synthetic material comprising a synthetic material, which is preferably a thermoplastic material, such as PVC (polyvinyl chloride), PP (polypropylene), PET (polyethylene terephthalate) or PETG (glycol-modified polyethylene terephthalate), and a filler material. As filler material, preferably calcium carbonate is applied.

[0153] The example decorative panel 1 is provided with a shaped edge on the pair of longitudinal edges 2-3 and on the pair of short edges 4-5. The shaped edge is provided with a coupling portion 13 such that two such decorative panels 1 can be coupled at the respective edges 2-3 and in the coupled state a locking in a direction V1 perpendicular to the plane of the coupled panels and / or in the plane and perpendicular to the respective edges 2-3 is obtained. In the example, the coupling portion is essentially formed as a tongue 14 and a groove 15, wherein the tongue 14 and the groove 15 are provided with a locking portion 16 to prevent the tongue and the groove from separating.

[0154] Alternatively, in Figure 2As shown in the example of Fig. 1, the decorative panel 1 can comprise an additional substrate layer 7A between the substrate 7 and the thermoplastic film 12, as indicated by the dashed line. The additional layer 7A can comprise a foamed thermoplastic material. In case the substrate 7 comprises PVC, the foamed thermoplastic material can be foamed PVC, and preferably, the amount of plasticizer comprised by the foamed thermoplastic material is higher than the amount of plasticizer present in the substrate 7. Preferably, the additional substrate layer 7A can be laminated or glued on top of the substrate 7, or the additional substrate layer 7A can be co-extruded with the substrate 7 when the substrate 7 is extruded. The substrate 7 and the additional substrate layer 7A can also be indicated together as a substrate having two sub-layers.

[0155] Figure 3 A method for manufacturing decorative panels of the type Figure 1 and Figure 2 is shown. The method comprises a step S1 of providing a web, sheet or slab of material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8, and a step S2 of providing one or more lowered areas 6A in the web, sheet or slab of material 17. The method further comprises a step of further processing, preferably at least dividing, the web, sheet or slab of material 17 into one or more of the plurality of decorative panels 1, wherein at least a portion of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of the pair of opposite edges 2-3 of the decorative panel 1.

[0156] First, and not shown here, the step of providing a web, sheet or slab of material 17 comprises providing a material in a continuous form and cutting at least the substrate 7 transversely from the material, e.g. by means of a punch, a guillotine or a flying saw. The transversely cut edges 18 can result in a lack of squareness of the obtained web, sheet or slab of material 17. The material can be provided at least by extrusion, and preferably, a top layer is subsequently provided on the extruded material, e.g. by means of hot lamination of one or more pre-made sheets, e.g. a printed decorative foil and a transparent foil. During extrusion, a first reference edge 19 can be provided by machining and straightening the longitudinal edges of the web, sheet or slab of material 17, preferably before transversely cutting.

[0157] Figure 4 A cross-section of the provided web, sheet or slab of material 17 is shown, as well as a profile 20 of the coupling portion 13 to be obtained in the shaped edge. The provided web, sheet or slab of material 17 can comprise recesses formed in the transparent layer, e.g. mimicking wood pores.

[0158] Figure 4 It is further shown that the first reference edge 19 is provided at a predetermined distance D1 from the lowered edge area 6 or upper edge 11 to be obtained.

[0159] In Figure 3 the example, the step S2 of providing one or more lowered areas 6A in the slab, sheet or board material 17 comprises at least a discontinuous pressing operation by means of a press 23 with a pressing die 22, as shown in Figure 5 Before the pressing operation, at least a second reference edge 21 is machined to the at least base plate 7, wherein the second reference edge 21 is at a predetermined distance D2 from and preferably parallel to one of the pair of opposite edges 4-5. In this case, the second reference edge 21 is parallel to the upper edge 11 of the pair of short opposite edges 4-5.

[0160] The first reference edge 19 is used to align the slab, sheet or board material 17 with the pressing die 22 in which the slab, sheet or board material 17 is driven into the press 23 by means of a carriage and / or gripper 24, wherein the slab, sheet or board material 17 is fed into the press 23 with the first reference edge 19 in a predetermined position P, wherein for example a precision is allowed that allows a tolerance of 0.25 mm or less. The press 23 can be equipped with one or more stop surfaces to support the precise positioning.

[0161] It can be clearly seen that in this case the second straightened edge or second reference edge 21 is provided in the device 25, wherein the first straightened edge 19 is used as a reference. In the example, the second straightened edge 21 is provided during the feeding of the slab, sheet or board material 17 into the press 23.

[0162] Figure 3 It is shown that a saw or milling cutter 26 can be positioned to provide the second straightened edge 21. Optionally, also the other transverse edge 18A can be straightened by means of a second saw or milling cutter 26A.

[0163] Preferably, the one or more reference edges 19-21 are used as a reference in further processing. Preferably, but not shown here, the one or more reference edges 19-21 are used as a reference for dividing the slab, sheet or board material 17. Preferably, the slab, sheet or board material 17 is divided into panels 1 having approximately the desired dimensions of the decorative panel 1. Preferably, the further processing comprises at least providing (more specifically milling) a shaped edge to the pair of opposite edges 2-3.

[0164] Figure 6The possibility of further processing is illustrated. A slab, sheet, or plate-like material 17 is pushed against a fixed ruler 28 by means of, for example, a spring system 29, such that the fixed ruler 28 contacts the first reference edge 19. The slab, sheet, or plate-like material 17 is then divided into one or more semi-finished panels 30 by a dividing device 31 (e.g., by means of multiple saw blades). A secondary reference edge 19A parallel to the first reference edge 19 is then created by the dividing device 31. The secondary reference edge 19A can be used to prevent one or more descending edge regions 6A from being milled away in further processing, because the secondary reference edge 19A is at a known distance from the one or more descending edge regions, which is not shown here.

[0165] Subsequently, the semi-finished panel 30, having approximately the required size of the decorative panel 1, is placed against the fixed ruler 32 with its reference edge 19A facing downwards, and its entire upper surface 10 facing downwards. The decorative panel 1 is held in the position against the fixed ruler 32, for example, as... Figure 6 As shown, the semi-finished panel 30 is then fed into a first milling machine 34, which includes multiple milling tools 36 on both sides, to mill the shaped edges of the pair of opposing edges 2 to 3. After leaving the first milling machine 34, the semi-finished panel is pushed against a fixed scale 37 with its short side by means of a spring system 38. The semi-finished panel then enters a second milling machine 39 by means of a cam chain 40, which includes multiple milling tools 41 on both sides, to mill the shaped edges at the short opposing edges 4 to 5. The milling tools 41 are positioned such that the descending edge region extending horizontally H on the decorative panel 1 is not milled away. Since the reference edges 19A, 21 are aligned with the fixed scales 32, 37, the position of the descending edge region 6 is known and the necessary positions of the milling tools 36, 41 can be calculated. After milling the pair of short edges 4 to 5, the finished decorative panel 1, including one or more descending edge regions 6, has the desired dimensions.

[0166] Figure 7 Possible methods for manufacturing decorative panel 1 according to a second aspect of the invention are shown, along with other methods. This method includes step S3, which involves extruding a filled synthetic composite material mixture. Here, the filled synthetic composite material mixture is fed into an extruder 42. Preferably, the filled synthetic composite material mixture comprises a synthetic material and a filler material. The synthetic material is a thermoplastic material, preferably polyvinyl chloride containing 5 phr or less of a plasticizer or completely free of plasticizer, and the filler material may be calcium carbonate. The mixture is then extruded via a die 43 to provide a substrate 7 in a continuous form. The die 43 may be provided with an adapter nozzle opening, for example, to accommodate... Figure 10 and Figure 11 The top recess and / or bottom recess 44 to 45 in the substrate 7 shown.

[0167] The method further comprises a step S4 of calendering the substrate 7 to calibrate the substrate 7 and to move the substrate in the feed direction F. The method further comprises a step S5 of laminating the thermoplastic film 12 onto the substrate 7 by means of a laminating roll 46, the thermoplastic film comprising the printed pattern 8 and the transparent layer 9.

[0168] The method further comprises a step S6 of at least partially providing the recesses 47 in the transparent layer 9. Preferably, the step S6 is at least partially performed separately from, preferably before, the step S7 or the step S2 of providing the lowered areas 6A in the web, sheet or plate-like material 17. Preferably, the step S6 of providing the recesses 47 in the transparent layer 9 is at least partially performed by means of an embossing roll 48, wherein the embossing roll 48 is preferably heated to a temperature in the range of 140°C to 180°C. Preferably, the embossing roll 48 is used in combination with a counter-embossing roll 49. In case the embossing roll 48 is used to at least partially provide the recesses 47 in the transparent layer 9, preferably the web, sheet or plate-like material 17 comprising the transparent layer 9 is provided to the embossing roll 48 in a continuous form.

[0169] The method can further comprise a step S7 of providing one or more lowered areas 6A in the web, sheet or plate-like material by means of an additional embossing roll 50. The additional embossing roll 50 is preferably used in combination with an additional counter-embossing roll 51. The additional embossing roll 50 is then heated, preferably in the range of 130°C to 160°C. According to a further embodiment of the present application, the recesses 47 at least partially provided in the step S6 can also be pre-formed in the step S6 and fully formed in the step S7 of providing one or more lowered areas 6A in the web, sheet or plate-like material 17 by means of the additional embossing roll 50. It can also be preferred that the lowered areas 6A are pre-formed during the step S6 of at least partially providing the recesses in the transparent layer 9 and fully formed during the step S7 of providing one or more lowered areas 6A by means of the additional embossing roll 50. The additional embossing roll 50 comprises a circumference 52 comprising at least one protrusion 53 corresponding to the position of at least one of the lowered areas 6A. This is shown in Figure 9 , which is a cross-sectional view of the additional embossing roll 50 with the web, sheet or plate-like material 17 and the additional counter-embossing roll 51, denoted by the line IX-IX. An alternative embodiment of the step S7 of providing one or more lowered areas by means of the additional embossing roll 50, denoted by the box F12, is shown in Figure 12 .

[0170] The web, sheet or plate-like material 17 in a continuous form is subsequently cut into a web, sheet or plate-like material 17 in a non-continuous form by means of a cutting machine 54, for example as shown in Figure 7 .

[0171] Preferably, in case the optional step S7 of providing one or more lowered areas 6A in the web, sheet or plate-like material 17 by means of an additional embossing roller 50 is not performed, the method further comprises a step S8 of applying an additional component 55 in the plurality of recesses 47. A preferred embodiment of the step S8 of applying an additional component 55 (indicated by block F13) is shown in Figure 13 .

[0172] After the step S8, the method further comprises a step S2 of providing one or more lowered areas 6A in the web, sheet or plate-like material 17 by means of a press 23, preferably a discontinuous press 23. According to a further embodiment of the present application, the recesses 47 provided at least partially in the step S6 can also be pre-formed in the step S6 and fully formed in the step S2 of providing one or more lowered areas 6A in the web, sheet or plate-like material 17 by means of a press 23, preferably a discontinuous press 23. It can also be preferred that the lowered areas 6A are pre-formed during the step S6 of providing the recesses S6 at least partially into the transparent layer and fully formed during the step S2 of providing one or more lowered areas by means of a press 23, preferably a discontinuous press 23.

[0173] The press 23, preferably a discontinuous press 23, of the first possibility preferably comprises a die portion 22, wherein the die portion 22 has an integral surface 56 comprising at least one protrusion 57 contacting the web, sheet or plate-like material during the pressing operation, preferably on that portion of the die surface, characterized in that the protrusion 57 at least corresponds to the position of the lowered areas 6A. A detailed view of a preferred embodiment of the preferably discontinuous press 23 (indicated by block F10) is shown in Figure 10 .

[0174] Figure 7 A perspective view of the web, sheet or plate-like material 17 obtained after the step S2 is shown. A preferred embodiment of the web, sheet or plate-like material 17 (indicated by block F8) is shown in Figure 8 .

[0175] Figure 8 A perspective view of the web, sheet or plate-like material 17 obtained after the step S2 is shown. A preferred embodiment of the web, sheet or plate-like material 17 (indicated by block F8) is shown in Figure 7The diagram refers to a perspective view of a slab, sheet, or plate-like material 17, as referenced in F8. The slab, sheet, or plate-like material 17 preferably includes at least a printed pattern 8 and a transparent layer 9, as well as a reduced region 6A on the long sides 2 to 3 and the short sides 4 to 5 of the decorative panel 1 to be obtained. When the reduced region 6A is located on the long sides 2 to 3 of the decorative panel 1 to be obtained from the slab, sheet, or plate-like material 17, the reduced region 6A extends continuously along its entire length; when the reduced region 6A is located on the short sides 4 to 5 of the decorative panel 1 to be obtained, the reduced region extends continuously along its entire width. Figure 8 Several technical regions 58 are also shown. In a technical sense, region 58 refers to a region in which the material is at least partially absent from the decorative panel 1. Technical region 58 preferably includes at least partially the connecting portion 13 for the decorative panel 1 to be obtained, and technical region 58 is preferably defined by a lowered region 6A on the long sides 2 to 3 and the short sides 4 to 5 of the decorative panel 1 to be obtained. Figure 8 The image also shows magnified details to illustrate the continuity of reduced region 6A.

[0176] Figure 9 Cross-sectional views of the additional impression roller 50, the blank, sheet, or plate material 17, and the additional counter-pressure roller 51 are shown, as illustrated by... Figure 7 The additional impression roller 50 is heated to a temperature preferably in the range of 130°C to 160°C. The additional impression roller 50 includes a circumferential surface 52, which includes at least one protrusion 53 corresponding to the position of at least one of the plurality of lowered regions 6A. The blank, sheet, or plate material 17 preferably includes a thermoplastic film 12, a printed pattern 8, and a transparent layer 9. The lowered region 6A preferably includes at least a portion of the substrate 7, at least a portion of the thermoplastic film 12, at least a portion of the printed pattern 8, and at least a portion of the transparent layer 9. The outline of the connecting portion 20 preferably disposed in the decorative panel 1 to be obtained is also... Figure 9 The diagram shows the approximate location of the lowered region 6A. It is thus clear that the lowered edge region 6 in the decorative panel 1 includes at least a portion of the lowered region 6A. Preferably, the blank, sheet, or plate material 17 is provided in a continuous form, and the blank, sheet, or plate material 17 has some residual heat from previous processing steps (such as extrusion S3 and / or lamination S5). Figure 9 The location of the technical region 58 present in the blank, sheet, or plate material 17 is also shown. It can be clearly seen from this figure that multiple decorative panels 1 can be obtained from a single blank, sheet, or plate material 17. Enlarged details of an alternative embodiment of the cross-sectional view of the additional impression roller 50 (labeled by box F11) are also shown. Figure 11 As shown in the image.

[0177] As Figure 7 indicated in F10, Figure 10 A detailed view of a preferred embodiment of a discontinuous press 23 for providing a lowered area 6A in a slab, sheet or board material 17 is shown. The discontinuous press 23 is preferably heated to a temperature in the range of 100°C to 150°C, while the slab, sheet or board material 17, more specifically its overall surface 10, can also be heated to a temperature in the range of 25°C to 110°C by means of radiation and / or convection prior to the step of providing the lowered area 6A. In another preferred embodiment, the discontinuous press 23 has a temperature in the range of 25°C to 75°C during the step S2. Then preferably, the slab, sheet or board material 17 is heated to a temperature in the range of 60°C to 110°C.

[0178] The discontinuous press 23 preferably comprises a die portion 22, wherein the die portion 22 has an overall surface 56, which preferably comprises at least one protrusion 57 on that portion of the die surface which contacts the slab, sheet or board material 17 during the pressing operation, wherein the protrusion 57 at least corresponds to the location of the lowered area 6A. The one or more protrusions 57 preferably extend from an adjacent portion 59 of the overall surface 56 of the die portion 22, the height D3 of the one or more protrusions being greater than the depth D4 of the lowered area 6A. Alternatively, the one or more protrusions 57 preferably extend from an adjacent portion 59 of the overall surface 56 of the die portion 22, and the height of the one or more protrusions is greater than 35% or even greater than 50% of the thickness of the slab, sheet or board material 17.

[0179] The slab, sheet or board material 17 preferably comprises a thermoplastic film 12, a printed pattern 8 and a transparent layer 9. The lowered area 6A preferably comprises at least a portion of the substrate 7, at least a portion of the thermoplastic film 12, at least a portion of the printed pattern 8 and at least a portion of the transparent layer 9. The profile 20 of the coupling portion 13, which is preferably provided in the decorative panel 1 to be obtained, is also shown in Figure 10 F10 to further indicate the approximate location of the lowered area 6A. It is clear from this that the lowered edge area 6 in the decorative panel 1 comprises at least a portion of the lowered area 6A. Figure 10 The location of the technical area 58 present in the slab, sheet or board material 17 is also shown. It is clear from this figure that a plurality of decorative panels can be obtained from one slab, sheet or board material 17.

[0180] In this preferred embodiment, the technical area 58 is provided with one or more recesses 45 at the underside of the slab, sheet or plate-like material 17. The bottom recesses 45 located in the technical area 58 can be used for the formation of the lowered areas 6A. The bottom recesses 45 in the one or more technical areas 58 are preferably provided at least partially by milling and / or sawing and / or cutting, but can also be provided at least partially by means of coining and / or pressing. Another possibility is that the recesses 45 in the one or more technical areas 58 are provided by means of extrusion by means of a die 43 with adapted slot nozzle openings. The bottom recesses 45 can be provided in a variety of different shapes.

[0181] Figure 11 An enlarged detail of an alternative embodiment (indicated by box F11) of a cross-sectional view of an additional coining roll 50 is shown as Figure 9 An enlarged detail of an alternative embodiment (indicated by box F11) of a cross-sectional view of an additional coining roll 50 is shown as

[0182] The substrate 7 can comprise one or more local stress zones 61. Such local stress zones 61 can result from the step S2 or step S7 of providing lowered areas in the slab, sheet or plate-like material 17, especially when the lowered areas 6A are obtained by means of a pressing operation by means of, for example, a coining roll 50 or a discontinuous press 23. Preferably, the local stress zones 61 are mainly present in the overhanging portions 63 of the tongues 14 and / or in the lower lip 64 of the grooves 15 and / or in the upper lip 65 of the grooves 15. Preferably, the local stress zones 61 affect as little material as possible, and the horizontal distance D7 of the local stress zones 61 from the thinnest section 62 of the lower lip 64 of the groove 15 is between 0.1 mm and 1 mm. Figure 14 An enlarged detail of an alternative embodiment (indicated by box F14) of a lowered area 6A of a slab, sheet or plate-like material 17 is shown in

[0183] Figure 12 An enlarged detail of an alternative embodiment (indicated by box F14) of a lowered area 6A of a slab, sheet or plate-like material 17 is shown in Figure 7An alternative embodiment of the additional impression roll 50 is shown in the middle and is denoted by the box F12. In this alternative embodiment, preferably during the step S7 of providing one or more lowered areas 6A, the slab, sheet or plate-like material 17 extends along the circumference of the additional impression roll 50 over an arc-shaped section 66 of the impression roll. This means that, when viewed in cross-section and in the feed direction F, the slab, sheet or plate-like material 17 initially contacts the additional impression roll 50 at a first point 67 and then moves along the circumference of the additional impression roll 50 to a second point 68 at which the slab, sheet or plate-like material 17 interrupts the contact with the additional impression roll 50, wherein the arc-shaped section 66 of the circumference is defined between the first point 67 and the second point 68. The arc-shaped section 66 preferably encompasses an angle A which is in the range of 0° to 90°. It can be clearly seen that this angle is defined between a radius 69 of the additional impression roll 50 which passes through the first point 67 and the second point 68.

[0184] Figure 13 A preferred embodiment of the step S8 of applying the additional composition 55 in the plurality of recesses 47 in the transparent layer 9 by means of the application device 70 is shown. Preferably, the method further comprises a step of controlling the amount of additional composition 55 which is fed into the nip 71 between the two rolls and which is applied on the slab, sheet or plate-like material 17. The step of controlling can be performed by the application device 70.

[0185] The application device 70 preferably comprises a doctor roll 72 and an application roll 73, and the amount of additional composition 55 which is applied on the slab, sheet or plate-like material 17 can be controlled by varying the distance between the doctor roll 72 and the application roll 73 and / or by varying the rotational speed of the doctor roll 72 and / or the application roll 73. Preferably, the doctor roll 72 and the application roll 73 are in contact during the application of the additional composition 55, and the circumferential surface 74 of the application roll 73 is pressed into by the doctor roll 72. Preferably, the hardness of the circumferential surface 74 of the application roll 73 is between 5 Shore and 25 Shore (preferably about 15 Shore), and the circumferential surface 74 preferably comprises polyurethane (PU).

[0186] Preferably, after the additional composition 55 has been applied into the plurality of recesses 47, at least some of the additional composition 55 is removed by a removal roll 75 and / or by brushing and / or grinding, not shown here. The hardness of the circumferential surface of the removal roll 75 is preferably between 20 Shore and 80 Shore (preferably about 60 Shore). Preferably, the removal roll 75 rotates in the opposite rotational direction as the application roll 73.

[0187] Figure 14 A preferred embodiment of the step S9 of removing the additional composition 55 from the plurality of recesses 47 is shown in the right part of Fig. 6. The step S9 is performed by means of the removal device 76. The removal device 76 preferably comprises a doctor roll 77 and an application roll 78, and the amount of additional composition 55 which is removed from the plurality of recesses 47 can be controlled by varying the distance between the doctor roll 77 and the application roll 78 and / or by varying the rotational speed of the doctor roll 77 and / or the application roll 78. Preferably, the doctor roll 77 and the application roll 78 are in contact during the removal of the additional composition 55, and the circumferential surface 79 of the application roll 78 is pressed into by the doctor roll 77. Preferably, the hardness of the circumferential surface 79 of the application roll 78 is between 5 Shore and 25 Shore (preferably about 15 Shore), and the circumferential surface 79 preferably comprises polyurethane (PU). Figure 11An enlarged detail of an alternative embodiment of the lowered area 6A of the slab, sheet or plate-like material 17, indicated by block F14. In the alternative embodiment, an additional component 55 has been applied in the plurality of depressions 47 in the transparent layer 9. When the additional component 55 is applied by means of an application device 70 comprising at least one application roller 73, the areas 77 of the transparent layer 9 adjacent to the depressions 47 can also have at least some of the additional component 55 applied thereon. At least some of the additional component 55 can be removed by means of a removal roller 75 and / or by brushing and / or grinding. After the step of removing the additional component 55, for example by means of the removal roller 75, a residual film 76 of the additional component 55 can be present on the areas 77 of the transparent layer 9 adjacent to the depressions 47, since not all of the additional component 55 can be removed. The thickness of the residual film 76 can be between 0 and 50 micrometers, preferably less than 10 micrometers, preferably approximately 5 micrometers. After the removal step, the slab, sheet or plate-like material is provided with the lowered area 6A, which makes the lowered area 6A also include the residual film 76.

[0188] Figure 15 A cross-sectional view, indicated by line XV-XV, and a partial enlarged view of a partial cross-section, including a protrusion 78, of an alternative embodiment of an application roller 73, which is part of the application device 70 shown in Fig. 1. Figure 13 The application roller 73 has an outer surface 74 comprising at least one protrusion 78. The application roller 73 preferably contacts or is in close proximity to the slab, sheet or plate-like material 17 to be provided with the additional component 55. In this case, the application roller 73 itself directly delivers the additional component 55 to the slab, sheet or plate-like material 17 by means of its active coating surface 79. Preferably, the one or more protrusions 78 extend outwardly from an adjacent portion 80 of the outer surface 74 by a distance D8 of between 0 and 1 mm. The position of the at least one protrusion 78 preferably corresponds at least to the position of one of the plurality of lowered areas 6A, and / or, when the outer surface 74 comprises a plurality of protrusions 6A, to the positions of the plurality of lowered areas 6A and / or to the positions of other areas in which it is desired to apply the additional component 55 in an equal or lesser manner or not at all.

[0189] Preferably, the one or more protrusions 78 comprise a side portion 81 having a slope A2 with respect to the adjacent portion 80 of the outer surface 74 of the application roller 73, wherein the slope A2 is between 90° and 180°, and wherein the side portion 81 preferably extends at least 50 percent of the height of the one or more protrusions 78.

[0190] Figure 16 It is shown that Figure 13Figure 6 shows a perspective view of an alternative embodiment of the application device 70 shown in Figure 1. In this alternative embodiment of the device 70, the nip 71 between the doctor roll 72 and the application roll 73 can be divided into a plurality of nips 71 by providing at least one removable portion 82 between the doctor roll 72 and the application roll 73. Preferably, the at least one removable portion 82 directly contacts the rolls 72, 73. Preferably, the divided nips 71 are each fed with an additional ingredient 55. The application roll 73 directly delivers the additional ingredient 55 to the entire upper surface 10 of the slab, sheet or plate material 17 by means of its active coating surface 79. Preferably, the placement of the at least one removable portion 82 at least corresponds to the position of one of the plurality of lowered areas 6A, and / or, when a plurality of removable portions 82 is provided between the doctor roll 72 and the application roll 73, to the position of the plurality of lowered areas 6A and / or to the position of other areas where it is desired to apply the additional ingredient 55 in an equal or lesser manner or where it is not desired to apply the additional ingredient.

[0191] Figure 3 In Figure 6, an optional preheating device 83 (e.g. infrared or near-infrared radiator) is also shown in dashed lines, which preheating device is used to heat the slab, sheet or plate material 17 prior to the step S2 of providing the lowered areas 6A. Such a preheating device 63 can comprise a heating table or plate for contacting the bottom of the slab, sheet or plate material 17 and an infrared heater for heating the upper surface 10 of the slab, sheet or plate material 17.

[0192] Figure 5 It is shown that the press mold 22 can comprise a first protrusion 57 and an optional second protrusion 84, which second protrusion extends substantially parallel to the first protrusion 57. The first protrusion 57 corresponds to the position of the lowered area 6A. The second protrusion 84 corresponds to the technical area 58 or to a side portion 85 of the slab, sheet or plate material 17, which technical area or side portion is configured to be removed or at least partially removed in a further processing step. Here, the lowered area 6A forms a proximal delimitation of the side portion 85 or of the technical area 58, and the lowered area 6A is only spaced apart from the edge 86 of the slab, sheet or plate material 17 by means of the side portion 85. In examples, the first protrusion 57 and the optional second protrusion 84 have the same height Z and substantially the same cross-section. It is clear that in this case an additional lowered area 6B is provided in the side portion 85 or in the technical area 58 as shown in Figure 7. Figure 17

[0193] It is thus clear that, when the optional second protrusion 84 is present, Figure 5 The method and the press mold 22 shown in Figure 6 also form an embodiment of the ninth aspect listed in the summary of the application.

[0194] Figure 17 ​A slab, sheet or board-like material 17 is shown in which the lowered area 6A has been provided by means of a press tool 22 and the method has the features of the ninth aspect of the invention as well as other aspects. Here, the lowered area 6A of the decorative panel 1 that is only spaced apart from the edge 86 of the slab, sheet or board-like material 17 by the side portion 85 is also adjoined by an additional lowered area 6B that is located in the side portion 85 or the technical area 58. Figure 17 It is shown that the additional lowered area 6B located in the side portion 85 extends substantially parallel to the adjacent lowered area 6A that forms the proximal delimitation of the side portion 85. In Figure 17 In the example of Figs. 1 to 3, an additional lowered area 6B is provided in at least one side portion 85 and in the present case in both side portions 85 that is parallel to the pair of longitudinally opposite edges 2 to 3 of the decorative panel 1 in the slab, sheet or board-like material 17. In this case, an additional lowered area 6B is provided in at least one side portion 85 and in the present case in both side portions 85 that is parallel to the pair of short opposite edges 4 to 5 of the decorative panel 1 in the slab, sheet or board-like material 17.

[0195] It can be clearly seen that such a second protrusion 84 at the location of the side portion 85 has a meaning not only when using a non-continuous press 23. A second protrusion 84 has a similar effect when implemented on the impression roller 50, for example at the additional impression roller 50 shown in Figure 9 Preferably, such a second protrusion 84, although not shown in Figs. 1 to 3, would preferably be provided at the adjacent distal end of one or both outermost first protrusions 57. These second protrusions 84 would then provide an additional lowered area 6B in the side portion 85 of the slab, sheet or board-like material 17. Figure 9

[0196] Figure 18 A press tool 22 is shown that has a first protrusion 57 as well as a second protrusion 84 that extends parallel to the first protrusion. In particular, it relates to a press tool 22 that can be used to provide a lowered area 6A and an additional lowered area 6B in a slab, sheet or board-like material 17 by means of Figure 17 In this case, the second protrusion 84 is provided for achieving an additional lowered area 6B at all side portions 85 of the slab, sheet or board-like material. As explicitly pointed out in the foregoing, this is not necessarily the case and such a second protrusion 84 can only be present adjacent to one or more first protrusions 57 that provide a lowered area 6A to form a lowered edge area 6 at the longitudinal edges 2 to 3 or at the short edges 4 to 5 of the decorative panel 1.

[0197] Figure 18 ​It is further shown that in case the first protrusion 57 provides for forming the lowered edge region 6A of the lowered edge region 6 at the longitudinal edges 2-3 of the decorative panel 1, the length LI -L2 of the first protrusion 57 is larger than the length of the decorative panel 1 to be finally obtained, and / or in case the first protrusion 57 provides for forming the lowered edge region 6A of the lowered edge region 6 at the transverse or short edges 4-5 of the decorative panel 1, the length of the first protrusion is larger than the width of the decorative panel 1 to be finally obtained. In this case, the length LI -L2 of the first protrusion 57 is respectively larger than the length, width of the blank, sheet or plate-like material 17.

[0198] Figure 19 It is shown that the first protrusion 57 and the second protrusion 84 can be identical or substantially identical in shape, as shown in cross-section. In this case, the geometry of the first protrusion 57 and the second protrusion 84 are mirror images, but otherwise identical, for example having the same height Z. Alternatively, as shown by the dashed lines 87 and 88 respectively, the second protrusion 84 can have a maximum height Z1-Z2 which is smaller or larger than the height Z of the first protrusion 57, but preferably between 25% and 125% of the height Z of the first protrusion 57.

[0199] The first protrusion has a first maximum height position 89 and the second protrusion has a second maximum height position 90. The distance W between the first position 89 and the second position 90 is in this case about twice the height Z of the first protrusion 57.

[0200] It is noted that, Figure 5 It is shown that the distance W between the first position 89 and the second position 90 differs in embodiments at opposite side portions 85 of the blank, sheet and plate-like material 17. In this case, the distance W is larger at the side portion 85 adjacent to the edge 5 having the groove 15 than at the side portion 85 adjacent to the edge 4 having the tongue 14. The position of the second protrusion 84 is such that it is located directly above the technical area 58, more in particular directly above the material of the blank, sheet and plate-like material 17 to be completely removed. In this case, the influence of the more severe stress zone at the second protrusion 84 can be minimized.

[0201] Figure 20 It is shown that the first protrusion 57 and the second protrusion 84 form part of a common protrusion 91 protruding from the overall press plate surface 92. By means of the dashed lines, Figure 20 It is shown that the width B2 of the second protrusion 84 can be larger than the width Bl of the first protrusion 57. Preferably, the width Bl-B2 of the protrusions 57, 84 is considered at half their respective height Z. The opposite case is not excluded either, i.e. when the width of the second protrusion 84 is smaller than the width of the first protrusion 57. Such an example is given by means of Figure 21 It is shown that the width B2 of the second protrusion 84 can be larger than the width Bl of the first protrusion 57. Preferably, the width Bl-B2 of the protrusions 57, 84 is considered at half their respective height Z. The opposite case is not excluded either, i.e. when the width of the second protrusion 84 is smaller than the width of the first protrusion 57. Such an example is given by means of

[0202] It is noted that, Figure 18 The pressing tool 22 shown in Fig. 6 comprises a plurality of surface sections 93 to 93A which are all bounded on all sides by a first side portion 94 of the first protrusion 57. This first side portion 94 forms the surface of the drop edge region 6. Each surface section 93 corresponds to one decorative panel 1. The surface section 93A comprises at its long edge the first protrusion 57 which is spaced from the edge 95 to 96 of the pressing tool 22 only by a side portion 97 of the pressing tool 22 which does not correspond to a surface section 93 to 93A of a decorative panel 1; or in other words, the first protrusion 57 forms part of the outermost or distal surface section and wherein the side portion 97 of the pressing tool 22 comprises a second protrusion 84 which extends substantially parallel to the first protrusion 57. The second protrusion 84 can be provided between adjacent surface sections 93 to 93A, however, this is not shown here. In fact, the inventors have noticed that the close proximity of the first protrusions 57 of adjacent panels 1 surface sections 93 to 93A is providing a counter pressure which brings the defects in the local stress zone at the location of these first protrusions 57 to an acceptable level.

[0203] Figure 21 The most preferred embodiment of the pressing tool 22 according to the ninth aspect of the application is represented in Fig. 7. Here, the first protrusion 57 comprises a first side portion 94 which forms the surface of the drop edge region 6, wherein the first side portion 94 is curved and has a radius R1 of between 2 mm and 10 mm, preferably about 5 mm. The first protrusion 57 has a location 89 of maximum height Z, wherein the location 89 is positioned on a rounded segment having a radius R2 of between 0.2 mm and 1 mm, preferably about 0.5 mm. The first protrusion 57 has a location 89 of maximum height, wherein the maximum height is between 0.75 mm and 1.5 mm, preferably about 1.2 mm. The first protrusion 57 comprises a second side portion 98 opposite the first side portion 94, wherein the second side portion 98 is inclined at an angle A1 of 110° to 145° with respect to the overall surface 92 of the pressing tool 22. Figure 21It is clear that the first protrusion 57 has a cross-section substantially defined by the first side portion 94, the rounded segment and the second side portion 98. According to a ninth aspect, a second protrusion 84 is provided. The second protrusion 84 is in this case located at a side portion 97 of the press tool 22 adjacent to its edge 96. The second protrusion 84 has in this case the same height Z as the first protrusion 57. However, the width B2 of the second protrusion 84 at half the depth is significantly smaller than the width B1 of the first protrusion 57 at half the depth. The second protrusion 84 has side portions 99 that are substantially parallel and / or substantially vertical, for example extending at an angle of less than 10° or less than 5° with respect to the vertical. The second protrusion 84 has a U-shape, while the first protrusion 57 has a V-shape.

[0204] The distance W between the first position 89 and the second position 90 is in this case about 3 times the height Z. At another side portion of the press tool 22, the distance W can be different and preferably larger, for example about 5 to 6 times the height Z. Figure 21 The side portion 97 shown in Fig. 6 can be used to press a side portion 85 adjacent to the final edge 2, which edge has a coupling portion 13 in the form of a tongue 14.

[0205] Figure 22 It is shown that the second protrusion 84 can comprise inclined segments 100. In an example, the inclined segments 100 form an angle A2 of 5° with the first protrusion 57. A least squares line LSL through these segments 100 is parallel to the first protrusion 57.

[0206] Figure 23 It is shown that the second protrusion 84 can comprise segments 100 separated by interruptions 101 along the length of the first protrusion 57. The press tool 22 can comprise a third protrusion 102 located at a position shown in dashed lines and adjacent to one or more interruptions 101.

[0207] Figure 24 It is shown that the second protrusion 84 can be non-linear. In an example, the second protrusion 84 is wavy. A least squares line LSL through these segments 100 is parallel to the first protrusion 57.

[0208] Figure 25 It is shown that the second protrusion 84 can comprise undulating segments 100 separated by interruptions 101 along the length L1 of the first protrusion 57.

[0209] It is clear that, as Figures 18 to 25The second protrusions 84 shown in the figures can be combined in any configuration on a single press tool 22, and thus, the second protrusions 84 extending along a first side portion 97 of the press tool 22 can be different than the second protrusions 84 extending along another side portion 97 and / or different than the second protrusions 84 extending along a side portion 97 transverse thereto, i.e. having a different shape and / or height. It is also noted that the examples in the figures show first protrusions 57 and second protrusions 84 at all four side portions 97 of the press tool 22. However, it is not excluded that there are no first protrusions 57 and / or no second protrusions 84 at one or more of the side portions 97. For example, it can only be required to form a lowered edge region 6 at the longitudinal edges 2-3 of the decorative panel 1, such that no first protrusions 57 and thus no second protrusions 84 are required to press down the short edges 4-5 of the decorative panel 1.

[0210] The present application also relates to the following independent aspects and preferred embodiments defined by the following numbered paragraphs.

[0211] 1.- A method for manufacturing a decorative panel, wherein the method comprises at least: - a step S1 of providing a blank, sheet or plate of material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8; - a step S2 of providing one or more lowered regions 6A in the blank, sheet or plate of material 17; wherein, prior to the step S2 of providing the lowered regions 6A, the blank, sheet or plate of material 17 is optionally heated to a temperature comprised between 25°C and 110°C; - a step of further processing, preferably at least dividing, the blank, sheet or plate of material 17 into one or more of the plurality of decorative panels 1, wherein at least a portion of the one or more lowered regions 6A forms a lowered edge region 6 at one or both of the pair of opposite edges 2-3 of the decorative panel 1; characterized in that, the step of providing one or more lowered regions 6A in the blank, sheet or plate of material 17 comprises at least a preferably non-continuous pressing operation by means of a press 23 having a press tool 22, wherein at least one reference edge 19-21 is machined on the substrate 7 prior to and / or after and / or during the pressing operation, wherein the reference edge 19-21 is at a predetermined distance D1-D2 from at least one edge or at least one upper edge 11 of the pair of opposite edges 2-3 and preferably parallel to the at least one edge or the at least one upper edge.

[0212] 2. - The method according to numbered paragraph 1, characterized in that the step S1 of providing the slab, sheet or plate-like material 17 comprises first providing the material in a continuous form and cutting the material transversely into at least the base plate 7, for example by means of a punch, a guillotine or a flying saw.

[0213] 3. - The method according to numbered paragraph 2, characterized in that the material comprises at least the base plate 7 and a top layer.

[0214] 4. - The method according to numbered paragraph 2 or 3, characterized in that the material is provided at least by extrusion and, preferably, a top layer is subsequently provided on the extruded material, for example by means of a hot lamination of one or more pre-manufactured sheets of, for example, a printed decor foil 12 and a transparent foil, or a printed pattern is provided on the extruded material, for example by applying the ink directly on the extruded material, possibly with an intermediate layer of one or more primer layers, and / or one or more transparent layers are provided on the printed pattern by applying a varnish or a polymer substance in a liquid manner.

[0215] 5. - The method according to any one of the preceding numbered paragraphs, characterized in that the slab, sheet or plate-like material 17 is provided with at least a first edge that is machined straight.

[0216] 6. - The method according to numbered paragraph 5, characterized in that the at least one straight edge forms a first reference edge 19 and is used, for example, to align the slab, sheet or plate-like material 17 to the press mould.

[0217] 7. - The method according to numbered paragraph 6, characterized in that the slab, sheet or plate-like material 17 is driven into the press 23 by means of a trolley and / or a gripper 24, wherein the slab, sheet or plate-like material 17 is fed into the press 23 with the first reference edge 19 in a predetermined position P, wherein, for example, a precision is allowed that is 0.25 mm or less tolerance.

[0218] 8. - The method according to any one of numbered paragraphs 5 to 7, characterized in that the slab, sheet or plate-like material 17 is provided with at least a second edge 21 that is machined straight, wherein the second edge is perpendicular to the first edge.

[0219] 9. - The method according to numbered paragraph 8, characterized in that the second straight edge is provided in a device 25 in which the first straight edge is used as a reference.

[0220] 10. - The method according to numbered paragraph 8 or 9, characterized in that the second straight edge is provided when the slab, sheet or plate-like material 17 is fed into the press, when the slab is in the press 23 and / or when the slab, sheet or plate-like material 17 leaves the press 23.

[0221] 11. - The method according to any of the preceding numbered paragraphs, characterized in that one or more of the reference edges 19 to 21 are used as a reference for dividing the slab, sheet or board material. Preferably, the slab, sheet or board material 17 is divided into panels having approximately the desired dimensions of the decorative panel 1.

[0222] 12. - The method according to any of the preceding numbered paragraphs, characterized in that one or more of the reference edges 19 to 21 are used as a reference in further processing.

[0223] 13. - The method according to any of the preceding numbered paragraphs, characterized in that the method further comprises a step of providing recesses in the transparent layer 9, wherein preferably this step is at least partly performed separately from, preferably before, the step S2 of providing the lowered area 6A in the slab, sheet or board material 17.

[0224] 14. - The method according to any of the preceding numbered paragraphs, characterized in that the base plate 7 comprises a filler synthetic composite material, preferably the synthetic material is a thermoplastic material such as polyvinyl chloride and the filler material can be calcium carbonate, talc, coal.

[0225] 15. - A method for manufacturing a decorative panel 1, whether or not according to any of the preceding numbered paragraphs, characterized in that the method comprises: - a step S1 of providing a slab, sheet or board material 17 comprising a base plate 7 and a top layer applied on the base plate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8; - a step of providing recesses 47 in the transparent layer 9; - a step S2 to S7 of providing one or more lowered areas 6A in the slab, sheet or board material 17; - a step of further processing, preferably dividing, the slab, sheet or board material 17 into one or more of a plurality of decorative panels 1, wherein at least a part of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of a pair of opposite edges 2 to 5 of the decorative panel 1; characterized in that - the step S6 of providing recesses 47 in the transparent layer 9 is at least partly performed separately from, preferably before, the step S2 to S7 of providing the lowered area 6A in the slab, sheet or board material 17.

[0226] 16. - The method according to numbered paragraph 15, characterized in that the step S6 of providing the recesses 47 in the transparent layer 9 is at least partially performed by means of an embossing roller 48, wherein preferably the embossing roller 48 is heated to a temperature in the range of 140 °C to 180 °C.

[0227] 17. - The method according to numbered paragraph 15 or 16, characterized in that the web, sheet or plate-like material 17 is preheated by means of radiation and / or convection, or in that the web, sheet or plate-like material 17 comprises residual heat from a processing step prior to the step S2 to S7 of providing one or more lowered areas 6A. Preferably, the processing step comprises one or more of a lamination step, an embossing step and similar steps.

[0228] 18. - The method according to any one of numbered paragraphs 15 to 17, characterized in that the step S2 of providing one or more lowered areas 6A is performed by means of a discontinuous press 23, wherein preferably the discontinuous press 23 is heated to a temperature in the range of 100 °C to 150 °C.

[0229] 19. - The method according to numbered paragraph 18, characterized in that the press 23 comprises a die portion 22, wherein the die portion 22 has an integral surface 56 comprising at least one protrusion 57 on the surface that contacts the web, sheet or plate-like material 17 during the pressing operation, wherein the protrusion 57 corresponds to the position of the lowered area 6A.

[0230] 20. - The method according to numbered paragraph 19, characterized in that the one or more protrusions 57 extend from an adjacent portion 59 of the integral surface 56 by a distance that is larger than the depth of the lowered edge area 6, preferably the one or more protrusions 57 have a size in the range of 2 mm to 4 mm.

[0231] 21. - The method according to numbered paragraph 20, characterized in that the web, sheet or plate-like material 17, more in particular the upper surface 10 thereof, is heated to a temperature in the range of 25 °C to 110 °C.

[0232] 22. - The method according to any one of numbered paragraphs 18 to 21, characterized in that the pressure is applied by means of the discontinuous press 23 in the range of 10 kg / cm 2 to 40 kg / cm 2 .

[0233] 23. - The method according to any one of numbered paragraphs 18 to 22, characterized in that the recesses 47 are at least partially formed by means of the discontinuous press 23.

[0234] 24. - The method according to any one of numbered paragraphs 15 to 17, characterized in that the one or more lowered areas 6A are at least partly formed by means of the impression roller 48.

[0235] 25. - The method according to numbered paragraph 24, characterized in that the step S7 of providing the lowered areas 6A is at least partly performed by means of an additional impression roller 50, and wherein the additional impression roller 50 is heated to a temperature in the range of 130 °C to 160 °C.

[0236] 26. - The method according to numbered paragraph 24 or 25, characterized in that the impression rollers 48 to 50 comprise a circumference comprising at least one protrusion 53 corresponding to the position of at least one of the lowered areas 6A.

[0237] 27. - The method according to any one of numbered paragraphs 15 to 17, characterized in that the step S2 of providing the lowered areas 6A is at least partly performed by means of the press 23, preferably a discontinuous press 23, at a temperature in the range of 25 °C to 75 °C.

[0238] 28. - The method according to numbered paragraph 27, characterized in that the web, sheet or plate-like material 17 is heated to a temperature in the range of 60 °C to 110 °C.

[0239] 29. - The method according to any one of numbered paragraphs 15 to 28, characterized in that the web, sheet or plate-like material 17 comprises a bottom, and wherein the bottom comprises the underside of the base sheet 7 or the underside of the backing layer, and wherein the bottom comprises one or more recesses 47.

[0240] 30. - The method according to numbered paragraph 29, characterized in that the backing layer comprises a thermoplastic material.

[0241] 31. - The method according to numbered paragraph 29 or 30, characterized in that the method comprises a step of adding one or more recesses 47 to the bottom, and wherein this step is at least partly performed by means of the impression rollers 48 to 50 or the discontinuous press 23.

[0242] 32. - The method according to any one of numbered paragraphs 15 to 31, characterized in that the web, sheet or plate-like material 17 comprises one or more technical areas 58 which are at least partly removed in a further processing step.

[0243] 33. - The method according to numbered paragraph 32, characterized in that the one or more technical areas 58 comprise one or more recesses 44 to 45, and that the recesses 44 to 45 can be present at the underside and / or the top of the web, sheet or plate-like material 17.

[0244] 34. - The method according to numbered paragraph 33, characterized in that the recesses 44-45 are at least partly provided by means of embossing and / or pressing and / or extrusion during the manufacturing of the web, sheet or board material 17.

[0245] 35. - The method according to numbered paragraph 33 or 34, characterized in that the recesses 44-45 are at least partly provided by milling and / or sawing.

[0246] 36. - The method according to any one of numbered paragraphs 32-35, characterized in that the recesses 44-45 are obtained prior to the steps S2-S7 of providing one or more lowered areas 6A into the web, sheet or board material 17.

[0247] 37. - A method for manufacturing decorative panels 1, whether or not according to any one of the preceding numbered paragraphs, characterized in that the method comprises: - a step S1 of providing a web, sheet or board material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8; - a step S7 of providing one or more lowered areas 6A in the web, sheet or board material 17; - a step of further processing, preferably dividing, the web, sheet or board material 17 into one or more of the decorative panels 1, wherein at least a portion of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of the pair of opposite edges 2-5 of the decorative panel 1; characterized in that, - the step S7 of providing one or more lowered areas 6A in the web, sheet or board material 17 is performed using embossing rolls 48-50 at a temperature of 130 °C or higher, preferably less than 200 °C, preferably about 170 °C, wherein preferably the surface 10 of the web, sheet or board material 17 has been pre-heated; and / or - the web, sheet or board material 17 is provided in a continuous form, wherein the further processing step comprises: cutting the web, sheet or board material 17 transversally as a first operation after the step S7 of providing the lowered areas 6A, and / or within a range of 10 m of providing the lowered areas 6A, and / or at a temperature of 100 °C or higher, preferably 200 °C or higher, for example about 240-250 °C.

[0248] 38. - The method according to numbered paragraph 37, characterized in that, preferably prior to the step S7 of providing one or more lowered areas 6A, the transparent layer 9 is at least partly coated.

[0249] 39. - The method according to numbered paragraph 37 or 38, characterized in that the impression roller 48-50 is used together with a counter-pressure roller 49-51, wherein preferably the peripheral surface 56 of the counter-pressure roller 49-51 has rubber or synthetic material or steel.

[0250] 40. - The method according to any one of the numbered paragraphs 37-39, characterized in that during the step S7 of providing one or more lowered areas 6A, the web, sheet or board material 17 is extended along the circumference of the impression roller 48-50 over an arc-shaped section 66 of the impression roller, and the arc-shaped section 66 encloses an angle A in the range of 0°-90°.

[0251] 41. - The method according to any one of the numbered paragraphs 37-40, characterized in that the transparent layer 9 comprises the recesses 47, and the recesses 47 are at least partly provided by the impression roller 48 or by the additional impression roller 50.

[0252] 42. - A method for manufacturing decorative panels 1, whether or not according to any one of the preceding numbered paragraphs, characterized in that the method comprises: - a step S1 of providing a web, sheet or board material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8, wherein the transparent layer 9 is provided with recesses 47; - a step S8 of applying an additional ingredient 55 in the recesses 47; - a step S2 of providing one or more lowered areas 6A in the web, sheet or board material 17; - a step of further processing, preferably dividing, the web, sheet or board material 17 into one or more of the decorative panels 1, wherein at least a portion of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of the pair of opposite edges 2-5 of the decorative panel 1; characterized in that - the step S8 of applying an additional ingredient 55 in the recesses 47 is at least partly performed before the step S2 of providing the lowered areas 6A into the web, sheet or board material 17.

[0253] 43. - The method according to numbered paragraph 42, characterized in that the printed pattern 8 comprises at least a pattern corresponding to at least one of the decorative panels 1.

[0254] 44. - The method according to numbered paragraph 42 or 43, characterized in that the step S8 of applying the additional component 55 in the plurality of depressions 47 is at least partially performed by means of at least the application device 70 and / or the doctor blade and / or by means of polishing and / or wiping the upper surface, wherein preferably the application device 70 comprises one or more application rollers 73.

[0255] 45. - The method according to any one of numbered paragraphs 42 to 44, characterized in that after applying the additional component 55 in the plurality of depressions 47, at least some of the additional component 55 is removed by means of the removal roller 75 and / or by brushing and / or grinding.

[0256] 46. - The method according to any one of numbered paragraphs 42 to 45, characterized in that the method further comprises a step of controlling the amount of additional component 55 applied on the decorative panel 1, and wherein preferably the step of controlling is performed by means of the application device 70.

[0257] 47. - The method according to numbered paragraph 46, characterized in that the application device 70 comprises a doctor blade roller 72 and an application roller 73, and in that the amount of additional component 55 applied on the decorative panel 1 is controlled by varying the distance between the doctor blade roller 72 and the application roller 73 and / or by varying the rotational speed of the doctor blade roller 72 and / or the application roller 73.

[0258] 48. - The method according to any one of numbered paragraphs 42 to 46, characterized in that the step S8 of applying the additional component 55 in the plurality of depressions 47 is performed by means of digital printing in register with the depressions 47.

[0259] 49. - The method according to any one of numbered paragraphs 42 to 48, characterized in that the step S7 of providing one or more lowered areas 6A in the web, sheet or board material 17 is performed by means of a platen roller 48 to 50.

[0260] 50. - The method according to numbered paragraph 49, characterized in that the platen roller 48 to 50 is used together with a counter-pressure roller 49 to 51, preferably the peripheral surface 56 of which has rubber or synthetic rubber or steel.

[0261] 51. - The method according to numbered paragraph 49 or 50, characterized in that the platen roller 48 to 50 has a circumference which comprises at least one protrusion 53 corresponding to the position of at least one of the lowered areas 6A.

[0262] 52. - The method according to numbered paragraph 51, characterized in that the protrusion 53 extends from an adjacent portion 60 of the circumference by a distance which is greater than the depth of the lowered area 6A.

[0263] 53. - The method according to any one of numbered paragraphs 42 to 48, characterized in that the step S2 of providing one or more lowered areas 6A in the slab, sheet or board is performed by means of a discontinuous or continuous cold press 23.

[0264] 54. - The method according to any one of numbered paragraphs 42 to 48, characterized in that the step S2 of providing one or more lowered areas 6A in the slab, sheet or board is performed by means of a discontinuous or continuous hot press 23.

[0265] 55. - The method according to numbered paragraph 53 or 54, characterized in that the press 23 comprises a die portion 22, wherein the die portion 22 has an overall surface 56 comprising at least one protrusion 57, and wherein the protrusion 57 contacts the slab, sheet or board-like material 17 during the pressing operation, and in that the protrusion 57 corresponds in position to at least one of the lowered areas 6A.

[0266] 56. - The method according to numbered paragraph 55, characterized in that the protrusion 57 extends from an adjacent portion of the overall surface 56 of the die portion 22 by a distance which is greater than the depth of the lowered area 6A.

[0267] 57. - The method according to any one of numbered paragraphs 42 to 55, characterized in that the step of providing one or more lowered areas 6A in the slab, sheet or board is at least partly performed by milling out the lowered areas 6A in the slab, sheet or board-like material 17.

[0268] 58. - The method according to any one of numbered paragraphs 42 to 57, characterized in that the method further comprises the step of applying a top coat and / or a primer on the additional component 55.

[0269] 59. - The method according to numbered paragraph 58, characterized in that the method further comprises the step of curing the primer and / or the top coat by means of radiation and / or heat.

[0270] 60. - The method according to numbered paragraphs 42 to 59, characterized in that the additional component 55 comprises a varnish, a paint, etc.

[0271] 61. - The method according to any one of numbered paragraphs 42 to 60, characterized in that the additional component 55 comprises a powder.

[0272] 62. - The method according to any one of numbered paragraphs 42 to 61, characterized in that the method further comprises the step of at least partly curing the additional component 55 by means of radiation and / or heat.

[0273] 63. - The method according to numbered paragraph 62, characterized in that the partial solidification of the additional component 55 is at least partially performed prior to the step S2 of providing one or more lowered areas 6A into the slab, sheet or board material 17.

[0274] 64. - The method according to numbered paragraph 63, characterized in that the partially solidified additional component 55 is fully solidified during and / or after the step S2 of providing one or more lowered areas 6A into the slab, sheet or board material 17.

[0275] 65. - The method according to any one of the numbered paragraphs 62 to 64, characterized in that the step of at least partially solidifying the additional component 55 by means of heat is realized by means of a pressing and / or embossing operation.

[0276] 66. - A method for manufacturing decorative panels 1, whether or not according to any one of the preceding numbered paragraphs, characterized in that the method comprises: - a step S1 of providing a slab, sheet or board material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8, wherein the transparent layer 9 is provided with a plurality of depressions 47; - a step S7 of providing one or more lowered areas 6A in the slab, sheet or board material 17; - a step S8 of applying an additional component 55 in the plurality of depressions 47; - a step of further processing, preferably dividing, the slab, sheet or board material 17 into one or more of the plurality of decorative panels 1, wherein at least a portion of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of the pair of opposite edges 2 to 5 of the decorative panel 1; characterized in that, - the step S8 of applying an additional component 55 in the plurality of depressions 47 is at least partially performed after the step S7 of providing lowered areas 6A into the slab, sheet or board material 17, wherein an apparatus is used to apply the additional component 55, wherein the apparatus applies the additional component 55 in an equal or lesser manner in the lowered areas 6A.

[0277] 67. - The method according to numbered paragraph 66, characterized in that the apparatus comprises at least one application roller 73, and wherein the application roller 73 has an outer surface 74 comprising at least one protrusion 78.

[0278] 68. - The method according to numbered paragraph 67, characterized in that the one or more protrusions 78 extend outwardly from an adjacent portion 80 of the outer surface by a distance D8 of between 0 mm and 1 mm.

[0279] 69. - The method according to any one of the previous numbered paragraphs 67 or 68, characterized in that the position of the one or more protrusions 78 corresponds with the position of the at least lowered area 6A.

[0280] 70. - The method according to any one of the previous numbered paragraphs 67 to 69, characterized in that the protrusions 78 comprise a side portion 81 having a slope A2 with respect to the adjacent portion 80 of the outer surface 74 of the application roller 73, wherein the slope A2 is comprised between 90° and 180°.

[0281] 71. - The method according to any one of the previous numbered paragraphs 67 to 70, characterized in that the one or more protrusions 78 have a hardness which is the same or preferably harder than the hardness of the adjacent portion 80 of the outer surface 74 of the application roller 73.

[0282] 72. - The method according to any one of the previous numbered paragraphs 66 to 71, characterized in that the device 70 comprises a plurality of active coating surfaces 79 rotating around the same axis, these surfaces being separated by a distance which is preferably at least greater than or equal to the width of the lowered area 6A.

[0283] 73. - The method according to any one of the previous numbered paragraphs 66 to 72, characterized in that it comprises a step of removal of at least some of the additional components 55 by means of the roller 75 and / or by means of scraping and / or grinding.

[0284] 74. - The method according to any one of the previous numbered paragraphs 66 to 73, characterized in that the device 70 comprises at least two rollers 72 to 73 and in that the additional components 55 are fed to the device so as to enter into a nip 71 between the rollers.

[0285] 75. - The method according to the previous numbered paragraph 74, characterized in that the nip 71 is separated into a plurality of separate nips 71 by at least one removable portion 82, and in that each nip 71 is fed with additional components 55.

[0286] 76. - The method according to the previous numbered paragraph 75, characterized in that the one or more removable portions 82 directly contact at least one of the rollers 72 to 73 and in that the width of the one or more removable portions 82 is greater than or equal to the width of the lowered area 6A.

[0287] 77. - A method for manufacturing a decorative panel 1, whether or not according to any one of the previous numbered paragraphs, characterized in that it comprises: - a step S1 of providing a web, sheet or plate-like material 17 comprising a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8, wherein the transparent layer 9 is provided with recesses 47; - a step S8 of applying an additional component 55 in the plurality of recesses 47; - a step of further processing, preferably dividing, the web, sheet or plate-like material 17 into one or more of the decorative panels 1; characterized in that - the step S8 of applying an additional component 55 in the plurality of recesses 47 is at least partially performed by digitally applying the additional component 55.

[0288] 78.- The method according to numbered paragraph 77, characterized in that the additional component 55 is at least partially applied by using inkjet printing.

[0289] 79.- The method according to numbered paragraph 77 or 78, characterized in that the printed pattern 8 is at least partially applied by digital printing.

[0290] 80. The method according to any of numbered paragraphs 77 to 79, characterized in that the recesses 47 are at least partially provided by a digital method.

[0291] 81.- The method according to any of numbered paragraphs 77 to 80, characterized in that the recesses 47 are aligned with the printed pattern 8.

[0292] 82.- The method according to any of numbered paragraphs 77 to 81, characterized in that the additional component 55 is curable by means of radiation and / or heat, for example UV-curable.

[0293] 83.- The method according to any of numbered paragraphs 77 to 82, characterized in that the transparent layer 9 has a similar chemical composition as the additional component 55, preferably both the transparent layer 9 and the additional component 55 are based on acrylic.

[0294] 84.- A decorative panel 1 obtained by a method having the characteristics according to any of the preceding numbered paragraphs.

[0295] 85- A decorative panel 1 having a substrate 7 and a top layer applied on the substrate, the top layer comprising at least a printed pattern 8 and a transparent layer 9 applied on the printed pattern 8, wherein the transparent layer 9 is provided with recesses 47, and wherein the panel comprises a dropped edge area 6 at one or both edges of a pair of opposite edges 2 to 5, characterized in that the plurality of recesses 47 are provided with an additional component 55, whereas at least part of the dropped edge area 6 is free of the additional component 55 or is only covered by a residual film of the additional component 55.

[0296] 86.- The decorative panel 1 according to numbered paragraph 85, characterized in that the printed pattern 8 extends from the overall upper surface of the decorative panel 1 towards and over at least a portion of the drop edge region 6.

[0297] 87.- The decorative panel 1 according to numbered paragraph 85 or 86, characterized in that the additional component 55 is present predominantly in the recesses 47 and preferably not in the regions between the recesses 47.

[0298] 88.- The decorative panel 1 according to any one of the numbered paragraphs 85 to 87, characterized in that the drop edge region 6 comprises local recesses 47, wherein a plurality of the local recesses 47 are also provided with the additional component 55.

[0299] 89.- The decorative panel 1 according to any one of the numbered paragraphs 85 to 88, characterized in that the additional component 55 is an opaque component.

[0300] 90.- The decorative panel 1 according to numbered paragraph 89, wherein the additional component 55 is a colorant, such as a dye or an ink.

[0301] 91.- The decorative panel 1 according to any one of the numbered paragraphs 85 to 90, characterized in that the substrate 7 comprises at least one or more materials from the list consisting of: polyvinyl chloride, polypropylene, polyethylene, polyurethane, polylactic acid, polyethylene terephthalate, wood fiber boards such as medium density fiberboard or high density fiberboard.

[0302] 92.- The decorative panel 1 according to any one of the numbered paragraphs 85 to 91, characterized in that the substrate 7 comprises a thermoplastic material.

[0303] 93.- The decorative panel 1 according to numbered paragraph 92, characterized in that the substrate 7 comprises a filler material.

[0304] 94.- The decorative panel 1 according to numbered paragraph 93, characterized in that the filler material comprises CaC03and / or wood fibers and / or sand and / or talc and / or limestone or the like.

[0305] 95.- The decorative panel 1 according to any one of the numbered paragraphs 92 to 94, characterized in that the substrate 7 comprises 5 phr or less of plasticizer or is free of plasticizer.

[0306] 96- The decorative panel 1 according to any one of the numbered paragraphs 85 to 95, characterized in that the recesses 47 each have a maximum depth of between 20 micrometers and 500 micrometers, and wherein the depth varies along a cross-section of the decorative panel 1.

[0307] 97.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 96, characterized in that the printed pattern 8 is provided on a carrier sheet.

[0308] 98.- The decorative panel 1 according to the previous numbered paragraph 97, characterized in that the carrier sheet comprises a thermoplastic material.

[0309] 99.- The decorative panel 1 according to the previous numbered paragraph 97, characterized in that the carrier sheet comprises paper.

[0310] 100.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 96, characterized in that the printed pattern 8 is printed directly on the substrate 7.

[0311] 101.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 100, characterized in that the printed pattern 8 is a digital printed layer.

[0312] 102.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 101, characterized in that the transparent layer 9 comprises a thermoplastic material.

[0313] 103.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 102, characterized in that the transparent layer 9 comprises a varnish and / or a coating.

[0314] 104.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 103, characterized in that the decorative panel 1 comprises at least at one pair of opposite edges 2 to 5 a coupling portion 13 enabling a mechanical locking between two such decorative panels 1.

[0315] 105.- The decorative panel 1 according to the previous numbered paragraph 104, characterized in that the substrate 7 comprises a local stress zone 61, and in that the local stress zone 61 comprises at least one zone of the coupling portion 13 which is not critical for the overall strength of the mechanical locking system between two decorative panels 1.

[0316] 106.- The decorative panel 1 according to any one of the previous numbered paragraphs 85 to 105, characterized in that the thickness of the residual film of the additional component 55 is between 0 μιη and 50 μιη.

[0317] 107.- A decorative panel 1 having a substrate 7 and a top layer applied to the substrate, which top layer comprises at least a printed pattern 8 and a transparent layer 9 applied to the printed pattern 8, wherein the substrate 7 is filled synthetic material and the panel comprises a lowered edge area 6 at one or both of a pair of opposite edges 2-5, wherein the pair of opposite edges 2-5 are provided with mechanical coupling means 13 allowing two such panels 1 to be locked to each other at the respective edges 2-5 in a vertical direction perpendicular to the plane of the coupled panels 1 and in a horizontal direction perpendicular to the edges and lying in the plane of the coupled panels 1, wherein the coupling means 13 are substantially shaped as a tongue comprising a portion 63 protruding from the respective edge and a recess bounded by an upper lip 65 and a lower lip 64, characterized in that the substrate 7 comprises a local stress zone 61 at one or more of the edges 2-5, wherein the stress zone 61 is present in the protruding portion 63 of the tongue and / or in the lower lip 64 of the recess and / or in the upper lip 65 of the recess.

[0318] 108.- The decorative panel 1 according to numbered paragraph 107, characterized in that preferably the local stress zone 61 is mainly present in the protruding portion 63 of the tongue and / or in the lower lip 64 of the recess and / or in the upper lip 65 of the recess.

[0319] 109.- The decorative panel 1 according to numbered paragraph 107 or 108, characterized in that preferably the local stress zone 61 is not present in parts of the mechanical coupling means 13 that are critical for the overall coupling tension of the mechanical coupling.

[0320] 110.- The decorative panel 1 according to any one of numbered paragraphs 107-109, characterized in that the local stress zone 61 affects the material as little as possible.

[0321] 111.- The decorative panel 1 according to any one of numbered paragraphs 107-110, characterized in that the local stress zone 61 is at a distance D7 from the thinnest section 62 of the lower lip 64 of the recess of between 0.1 mm and 1 mm.

[0322] 112.- A method for manufacturing a decorative panel, wherein the method comprises at least: - a step S1 of providing a slab, sheet or plate of material 17 comprising a substrate 7 and a top layer applied to the substrate, which top layer comprises at least a printed pattern 8 and a transparent layer 9 applied to the printed pattern 8; - a step S2 of providing one or more lowered areas 6A in the slab, sheet or plate of material 17; - a step of further processing, preferably at least dividing, the slab, sheet or board-like material 17 into one or more of the decorative panels 1, wherein at least a portion of the one or more lowered areas 6A forms a lowered edge area 6 at one or both of the pair of opposite edges 2-3 of the decorative panel 1; characterized in that the step of providing one or more lowered areas 6A in the slab, sheet or board-like material 17 comprises at least a preferably non-continuous pressing operation by means of a press 23 having a pressing die 22, wherein the pressing die 22 comprises at least a first protrusion 57 on the portion of the die surface that contacts the slab, sheet or board-like material 17 during the pressing operation, wherein the first protrusion 57 at least corresponds with the position of at least one of the plurality of lowered areas 6A, wherein the pressing die 22 comprises at least a second protrusion 84 extending substantially parallel to the first protrusion 57, wherein the second protrusion 84 contacts the slab, sheet or board-like material 17 during the pressing operation and corresponds with a portion of the slab, sheet or board-like material 17 that is removed in the further processing step.

[0323] 113.- The method according to numbered paragraph 112, characterized in that the slab, sheet or board-like material 17 comprises material for a plurality of decorative panels 1, wherein at least one of the plurality of decorative panels 1 is spaced apart from the edges of the slab, sheet or board-like material 1 only by a side portion 85 that is removed in the further processing step, wherein the second protrusion 84 corresponds with a portion within the side portion 85 and the at least one lowered area 6A corresponding with the first protrusion 57 forms a proximal delimitation of the side portion 85.

[0324] 114.- A pressing die 22 for use in the method according to numbered paragraph 112 or 113, characterized in that the pressing die 22 comprises a first protrusion 57 and a second protrusion 84.

[0325] 115.- The pressing die 22 according to numbered paragraph 114, characterized in that the first protrusion 57 and the second protrusion 84 have the same height, or wherein the difference in height between the first protrusion 57 and the second protrusion 84 is less than 15% of the height of the higher of the first protrusion (84) and the second protrusion 84.

[0326] 116.- The pressing die 22 according to numbered paragraph 114 or 115, characterized in that the cross-section of the first protrusion 57 and the cross-section of the second protrusion 84 are the same, or substantially the same.

[0327] The invention is not limited to the preferred embodiments described above, but these panels, pressing dies and methods can be realized according to several variants without departing from the scope of the invention.

Claims

1. A method for manufacturing a decorative panel, wherein, The method comprises at least: - a step (S1) of providing a slab, sheet or plate material (17) comprising a base panel (7) and a top layer applied on the base panel, the top layer comprising at least a printed pattern (8) and a transparent layer (9) applied on the printed pattern 8; - a step (S2) of providing one or more lowered areas (6A) in the slab, sheet or plate material (17); - a step of further processing the slab, sheet or plate material (17), preferably at least dividing it into one or more of the decorative panels (1), wherein at least a portion of the one or more lowered areas (6A) forms a lowered edge area (6) at one or both of the pair of opposite edges (2-3) of the decorative panel (1); characterized in that the step of providing one or more lowered areas (6A) in the slab, sheet or plate material (17) comprises at least a preferably non-continuous pressing operation by means of a press (23) having a pressing die (22), wherein the pressing die (22) comprises at least a first protrusion (57) on a portion of the die surface that contacts the slab, sheet or plate material (17) during the pressing operation, wherein the first protrusion (57) corresponds at least to the position of at least one of the plurality of lowered areas (6A), wherein the pressing die (22) comprises at least a second protrusion (84) extending substantially parallel to the first protrusion (57), wherein the second protrusion (84) contacts the slab, sheet or plate material (17) during the pressing operation and corresponds to a portion of the slab, sheet or plate material (17) that is removed in the further processing step.

2. The method of claim 1, wherein, The slab, sheet or plate material (17) comprises material for a plurality of the decorative panels (1), wherein at least one of the plurality of decorative panels (1) is spaced apart from an edge of the slab, sheet or plate material (1) only by a side portion (85) that is removed in the further processing step, wherein the second protrusion (84) corresponds to a portion within the side portion (85) and at least one of the lowered areas (6A) corresponding to the first protrusion (57) forms a proximal delimitation of the side portion (85).

3. The method according to claim 1 or 2, characterized in that at least one reference edge (19-21) is machined on the base panel (7) before and / or after and / or during the pressing operation, wherein the reference edge (19-21) is at a predetermined distance (D1-D2) from at least one of the pair of opposite edges (2-3) or at least one upper edge (11) and preferably parallel to this at least one of the pair of opposite edges or at least one upper edge.

4. The method of claim 3, wherein, The step (S1) of providing the slab, sheet or plate material (17) comprises first providing a material in continuous form and cutting at least the base panel (7) transversely from the material, for example by means of a punch, a guillotine or a flying saw.

5. The method of claim 4, wherein, The material comprises at least the base panel (7) and the top layer.

6. The method according to claim 4 or 5, characterized in that, The material is provided at least by extrusion and, preferably, the top layer is subsequently provided on the extruded material, for example by means of hot lamination of one or more pre-manufactured sheets of, for example, printed decor foil (12) and transparent foil, or by providing a printed pattern on the extruded material, for example by applying ink directly on the extruded material, possibly with an intermediate layer of one or more primer layers and / or by applying a varnish or polymer substance in liquid form on the printed pattern, providing one or more transparent layers.

7. The method according to any one of claims 3 to 6, characterized in that, The slab, sheet or plate material (17) is provided with at least a first edge that is processed to be straight.

8. The method of claim 7, wherein, The at least one straightened edge forms a first reference edge (19) and is used, for example, to align the slab, sheet or plate material (17) to the press mould.

9. The method of claim 8, wherein, The slab, sheet or plate material (17) is driven into the press (23) by means of a trolley and / or gripper (24), wherein the slab, sheet or plate material (17) is fed into the press (23) with the first reference edge (19) in a predetermined position (P), for example with an accuracy that allows a tolerance of 0.25 mm or less.

10. The method according to any one of claims 7 to 9, characterized in that, The slab, sheet or plate material (17) is provided with at least a second edge (21) that is processed to be straight, wherein the second edge is perpendicular to the first edge.

11. The method of claim 10, wherein, The straightened second edge is provided in a device (25) in which the straightened first edge is used as a reference.

12. The method according to claim 10 or 11, characterized in that, The straightened second edge is provided while the slab is in the press (23) and / or while the slab, sheet or plate material (17) is leaving the press (23).

13. The method according to any one of claims 3 to 12, characterized in that, One or more reference edges (19-21) are used as a reference for dividing the slab, sheet or plate material, preferably the slab, sheet or plate material (17) is divided into panels having approximately the desired dimensions of the decorative panel (1).

14. The method according to any one of claims 3 to 13, characterized in that, One or more reference edges (19-21) are used as a reference in the further processing.

15. The method according to any one of claims 3 to 14, characterized in that, The method further comprises a step of providing recesses in the transparent layer (9), wherein this step is preferably performed at least partially separately from the step (S2) of providing the lowered area (6A) in the slab, sheet or plate material (17), preferably before the step of providing the lowered area.

16. The method according to any one of claims 3 to 16, characterized in that, The base panel (7) comprises a filled synthetic composite material, preferably the synthetic material is a thermoplastic material, such as polyvinyl chloride, and the filler material is calcium carbonate, talc, coal.

17. A decorative panel having a substrate (7) and a top layer applied on the substrate, the top layer comprising at least a printed pattern (8) and a transparent layer (9) applied on the printed pattern (8), wherein, The substrate (7) is filled with synthetic material and the panel comprises a drop-down edge region (6) at one or both edges of a pair of opposite edges (2 to 5), wherein the pair of opposite edges (2 to 5) are provided with mechanical coupling means (13) which allow two such panels (1) to be locked to each other at the respective edges (2 to 5) in a vertical direction perpendicular to the plane of the coupling panels (1) and in a horizontal direction perpendicular to the edges and lying in the plane of the coupling panels (1), wherein the mechanical coupling means (13) are essentially shaped as a tongue comprising a portion (63) protruding from the respective edge and a recess delimited by an upper lip (65) and a lower lip (64), characterized in that the substrate (7) comprises a local stress zone (61) at one or more of the edges (2 to 5), wherein the local stress zone (61) is present in the protruding portion (63) of the tongue and / or in the lower lip (64) of the recess and / or in the upper lip (65) of the recess.

18. Decorative panel according to claim 17, characterized in that Preferably, the local stress zone (61) is mainly present in the protruding portion (63) of the tongue and / or in the lower lip (64) of the recess and / or in the upper lip (65) of the recess.

19. Decorative panel according to claim 17 or 18, characterized in that Preferably, the local stress zone (61) is not present in portions of the mechanical coupling means (13) which are critical for the overall coupling tension of the mechanical coupling.

20. Decorative panel according to any one of claims 17-19, wherein The local stress zone (61) is at a distance D7 of between 0.1 mm and 1 mm from the thinnest section (62) of the lower lip (64) of the recess.

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