FLOOR PANEL WITH JOINT, FLOOR PANEL ARRANGEMENT AND MANUFACTURING METHOD

Description

[0001] The invention relates to a floor panel with at least one chamfer, a floor panel arrangement, and a method for manufacturing such a floor panel.

[0002] Floor panels, such as laminate, are a popular flooring option made up of individual panels, each consisting of several layers. Typically, fiberboard panels are used, which are then covered with additional layers on the top and bottom surfaces. These layers can be made of materials such as paper, often soaked and impregnated with special resins. The top surface usually includes an overlay for increased durability, a decorative paper for visual appeal, and a wear-resistant top layer. The bottom surface typically includes a backing layer and, if necessary, an underlayment for impact sound insulation.

[0003] EP 3 578 383 B1 discloses a method for finishing a prepared panel. A decorative paper is applied to the top surface, followed by an abrasion-resistant overlay paper. A counter-layer is applied to the underside. During the pressing of the layers, a relief is pressed in, which can correspond to a chamfer.

[0004] A chamfer is a bevel, usually located at the edge of a floor panel, so that when two floor panels are placed next to each other, a complete joint is created by two chamfers located at the edge of the floor panels.

[0005] EP2774770B1 discloses a method for printing a wood-based panel with a decorative layer using a digital printing process and various layers of lacquer and / or resin as well as a protective layer.

[0006] PCT / EP2017 / 060710 describes a process for manufacturing an abrasion-resistant wood-based panel with a decorative layer and an overlay comprising several resin layers with abrasion-resistant particles and the pressing of the layer structure.

[0007] For the production of floor panels, the designs are printed digitally or analogously onto paper webs or sheet-shaped cores. The paper webs are typically impregnated, and the impregnated material is then pressed with an AC4 / AC5 paper overlay in short-cycle presses. After printing with a liquid overlay, the sheet cores are also pressed in short-cycle presses. Some press plates contain elements that become visible as joints between the floor panel transitions after further processing. In one process, the joint edges are milled. The milled chamfers are then painted over. Various colors are selected to match the designs.

[0008] The disadvantages of this technique are that the depth of the bevel is often weak with pressed chamfers, and panel joints appear flat or barely visible in the finished product. Furthermore, with milled chamfers, the normally abrasion-resistant and protected surface at the panel edges is damaged to apply color for a visual effect. This compromises the quality of the panels in the joint area. Additionally, there is a risk of the color peeling off due to abrasion, as it is not protected by an overlay.

[0009] DE102010022535A1 discloses a floor panel according to the preamble of claim 1. The method of claim 11 differs from the method of the aforementioned document in that the pressing of the chamfer takes place up to the plate-shaped core.

[0010] The invention is based on the technical problem of visually shaping the chamfer on a floor panel in such a way that it appears deeper while simultaneously remaining protected by an overlay. At the same time, in an arrangement of several floor panels, the joints resulting from each pair of adjacent chamfers at the edges of the floor panels should appear deeper.

[0011] The problem is solved by the subject matter of the independent patent claims. Advantageous embodiments of the invention are specified by the dependent patent claims, the following description, and the figures and their accompanying description.

[0012] One aspect of the invention relates to a floor panel according to claim 1.

[0013] The floor panel can be a floor slab, a panel, a ceiling panel, or a wall panel. The chamfer can be any portion of a joint when it is divided along its width. In particular, the chamfer can, for example, encompass half of the joint along its width. The width is the side along which the chamfer has a bevel in cross-section. The chamfer can be a straight bevel, for example, corresponding to half a V. The bevel can have any angle, for example, an angle between 30° and 60° to the plumb line. The chamfer can be shaped like a half-U or a quarter-circle, or have other shapes. The chamfer can encompass portions other than half of the complete joint, for example, one-third or two-thirds of a V, U, semicircle, etc.

[0014] The plate-shaped core has the form of a plate and is, for example, cuboid or approximately cuboid. The corners of the cuboid shape may be rounded. The plate-shaped core has a length, width, and height. The length of the plate-shaped core is greater than its width and height. The plate-shaped core is suitable for use with other layers to form a floor panel.

[0015] The visible printed layer is applied to the top surface of the plate-shaped core. This layer is visible when looking at the floor panel from above. The top surface is the side that is visible when the floor panel is used as flooring and is where furniture can be placed and where people can walk on it.

[0016] Furthermore, the floor panel features an overlay applied to the printed layer, at least partially covering it. This makes the printed layer less susceptible to damage from, for example, mechanical impacts such as walking on the floor panel or placing objects on it, thus increasing its durability and resistance. The overlay can be applied directly to the printed layer. It can be transparent, allowing the printed layer to remain visible through it. The overlay can be a layer of paper impregnated with resin and containing abrasion-resistant particles. Alternatively, it can be a liquid overlay.

[0017] The printed layer incorporates an effect to enhance the optical depth of the chamfer on a specific area of ​​the chamfer. This chamfer area is the region of the printed layer's top surface that has a bevel in cross-section. In other words, the effect is printed where the chamfer is pressed in. This effect is designed to make the chamfer appear deeper, potentially creating a 3D effect. The effect is intended to achieve a three-dimensional effect that is visually perceptible to humans.

[0018] The chamfer is pressed into the floor panel with a certain insertion depth.

[0019] This type of floor panel offers the advantage that the effect enhances the depth of the chamfer, making it appear deeper than if the chamfer were simply pressed. A further advantage is that the surface quality, as well as the durability and longevity of the chamfer, are improved by the overlay placed over the printed layer, compared to the usual method where the chamfer edge would have to be milled out before being painted.

[0020] The plate-shaped core can consist of, for example, a fiberboard, plastic, solid wood, stone, concrete, metal, or other materials. In one possible embodiment, the plate-shaped core can consist of high-density fiberboard (HDF). For example, the plate-shaped core can have a thickness of 6 mm to 12 mm. Possible values ​​for the length and width could be, for example, 2800 mm x 2070 mm. The size is not to be understood as limiting. An exemplary floor panel comprises a fiberboard with a substrate material, such as a paper web, arranged on its upper surface; the printing layer is arranged on the upper surface of the substrate material, which, for example, in one area...The panel features an effect at its edge or in its center to enhance the optical depth of the bevel; an overlay is applied to the top of the printed layer to protect it; the floor panel has a second area where the bevel is pressed in. These layers can be, for example, glued and / or pressed together. The underside of the floor panel, which differs from the top, can have one or more additional layers applied, such as a backing layer or a sound-absorbing layer.

[0021] One embodiment relates to a floor panel, wherein the visible printing layer is applied to a support material different from the plate-shaped core.

[0022] One embodiment relates to a floor panel in which the substrate material is a paper web.

[0023] The paper web can be applied to the plate-shaped core. The printing layer is applied to the paper web. Thus, the bevel is pressed through both the paper web and the plate-shaped core.

[0024] This offers the advantage that printing on paper allows for great technical freedom in terms of which exact colors, patterns, etc. can be printed.

[0025] The overlay can be a liquid overlay. Liquid overlays are typically used for directly decorated substrates. In directly decorated substrates, the substrate itself has a decorative element. The liquid overlay can comprise one or more liquid resin layers. Advantageously, at least one resin layer includes abrasion-resistant particles.

[0026] Possible examples of paper webs can have widths of up to 2070 mm. Possible examples of decorative paper webs can have a basis weight of 50-65 g / m². The paper web can be impregnated, for example, to make the colors more vibrant and / or to make the paper web less sensitive to liquids. The paper web can be pressed and / or glued onto the sheet-shaped core.

[0027] One embodiment relates to a floor panel, wherein at least one of the at least one chamfer is arranged such that it forms at least one edge of the floor panel.

[0028] The chamfer has a long and a shorter side, as well as a press-fit depth. The long side forms an edge of the floor panel. The shorter side corresponds to the width of the chamfer, along which the chamfer has a bevel in cross-section.

[0029] The edge preferably extends along the width of the floor panel. Alternatively, the edge can be arranged along the length of the floor panel.

[0030] One embodiment relates to a floor panel, wherein an edge opposite the main edge has at least one chamfer. The floor panel has at least two chamfers, each located on a different edge of the panel. This has the advantage that several of these floor panels can be placed next to each other, so that two chamfers of each adjacent floor panel abut each other, thus forming a complete joint between each pair of adjacent floor panels.

[0031] One embodiment relates to a floor panel, wherein the insertion depth of the joint is between 0.2 mm and 0.6 mm.

[0032] The insertion depth refers to the difference between the surface of the panel in the area where no chamfer is pressed, and the deepest point of the inserted chamfer.

[0033] One embodiment relates to a floor panel, wherein the effect features a color gradient. The color gradient comprises various colors, hues, and / or brightness levels, wherein, in particular, the color, hue, and / or brightness is darkest at the center of the width and / or increases along the width with distance from the center.

[0034] In this embodiment, the optical effect for enhancing the optical depth of the chamfer comprises a color gradient from one hue to another. In particular, the color gradient can be formed from a darker hue at the deepest pressed point of the chamfer to a lighter hue in an unpressed area.

[0035] The color gradient creates the visual impression that the darker areas are deeper than the lighter areas. If a darker shade is used at the deepest point of the chamfer, and a gradient to a lighter shade is applied, with the brightness increasing with distance from the deepest point of the chamfer, the optical effect is that the chamfer depth is increased.

[0036] For example, in a panel that is essentially brown, the bevel may have a color gradient from the same brown tone of the panel to a darker brown tone or to black at the deepest pressed point of the bevel.

[0037] Concrete examples of color gradients include, for instance, a gradient from black to a rich brown for printing the bevel. The gradient can be structured so that black is printed at the deepest point of the bevel and brown fades to the surface level. Additionally, markings can be incorporated into the print data at positions that will be removed during the subsequent processing steps of sawing and profiling. These markings can be used for alignment with cameras and a control unit of the impregnated paper sheets in the short-cycle press system and of the pressed panels during sawing. This ensures that the printed bevel is precisely positioned along the perimeter edges of the finished panel or at the locations of the pressed bevel.

[0038] One embodiment relates to a floor panel, wherein the floor panel has a second chamfer and a third chamfer such that the second chamfer and third chamfer form a joint, the joint being arranged within the floor panel.

[0039] This results in a complete joint within the floor panel. For example, this allows for herringbone patterns with a three-dimensional effect, where each herringbone appears optically deeper due to the enhanced depth effect of the chamfers. The chamfers, and thus the resulting complete joint, can have various cross-sectional shapes, insertion depths, and widths. The complete joint can have a V, U, semicircle, or other cross-sectional shape.

[0040] One embodiment relates to a floor panel wherein the printed layer has, in addition to the effect, a decoration different from the effect, which is arranged outside the at least one chamfer.

[0041] The advantage is that the floor panel can be given almost any look desired by the customer through the decor.

[0042] The decorative element is located in an area on the top surface of the printed layer, distinct from the area where the effect for enhancing the optical depth of the chamfer is applied. Possible decorative elements include imitations of wood, stone, concrete, cork, or other materials, as well as combinations and variations thereof, and fantasy patterns.

[0043] For example, a dark brown walnut decor can be used with a particularly deep chamfer effect, achieved through a combination of printed and pressed chamfering. The pressed texture of the decor can include areas where the chamfer(s) are embossed. The chamfer(s) may be visible at the edges of the finished panel. A gradient from dark gray to black is used for printing the chamfer. When creating the print data, an anthracite / black gradient can be created at the positions that correspond to the chamfered edge after further processing. The gradient can be structured, for example, so that black is printed at the deepest point of the pressed chamfer, fading to dark gray at the surface level. Additionally, markings can optionally be inserted into the print data at the positions that will be removed during the subsequent sawing and profiling steps.These systems can be used, on the one hand, to align the impregnated paper sheets in the KT (cutting machine) and, on the other hand, the pressed panels during sawing, using cameras and a control unit. This enables the precise positioning of the printed bevel(s) at the perimeter edges of the finished panel or at the positions of the pressed bevel. The printed color gradient at the pressed bevel positions makes it appear significantly deeper. The contrast to the mid-gray tone is high and stands out clearly from the rest of the installed flooring. Without the optical enhancement provided by the print in the area of ​​the pressed joint, the visual effect of a deep bevel would not be achievable.

[0044] Another example of a color gradient is a concrete decor in a medium gray tone with a particularly deep-looking chamfer, achieved through a combination of printed and pressed chamfering. For printing the chamfer, a gradient from dark anthracite to black is used. When creating the print data, an anthracite / black gradient is applied to the positions that will correspond to the joint edge after further processing. The gradient is structured so that black is printed at the deepest pressed point of the chamfer and then fades to brown down to the surface level. Additionally, markings can be inserted into the print data at the positions that will be removed during the subsequent sawing and profiling steps. These markings can be used for alignment with cameras and a control unit for the impregnated paper sheets in the short-cycle press and also for aligning the pressed panels during sawing.This ensures that the printed chamfers are precisely positioned along the edges of the finished panel or at the locations of the pressed chamfer. The printed color gradient at the pressed chamfer locations makes it appear much deeper, as the contrast with the mid-gray tone is high and it stands out clearly from the rest of the installed flooring.

[0045] In another possible embodiment, the chamfers can also be located in the middle of the floor panel, either additionally or exclusively, and not just at panel joints. This can be the case, for example, with a panel that imitates a herringbone pattern. The individual panel joints can be printed for visual enhancement and additionally pressed as a chamfer. Any color variation within the printable color gamut is possible to achieve the best possible depth or desired effect. This includes, for example, solid colors, linear gradients, or even textured / speckled variations thereof. Halftones or line combinations are also conceivable to achieve specific effects. There are virtually no limitations in this regard, especially with digital printing.

[0046] The printed color gradient at the points where the pressed bevel appears visually much deeper. The contrast with the natural color of the oak is high and stands out clearly from the rest of the laid flooring. This effect would not be achievable without the visual enhancement provided by the print in the area of ​​the pressed bevel. The surface quality of the bevel is significantly better protected with the pressed bevel over the printed gradient than if the edge had to be milled out for painting, as is the case with other common methods.

[0047] Optionally, the printed layer includes additional markings or control symbols, allowing the effect to be positioned precisely at a specific point on the pressed bevel using an optical alignment system. This offers the advantage of simple and precise positioning of the pressing equipment using the control symbols, ensuring that the pressed joint perfectly aligns with the optical effect of the bevel. Contrasting colors are preferably used for the control symbols. These symbols can include, for example, lines, dots, or combinations thereof. Preferably, the control symbols are located in areas that are not visible on the finished panel, for example, because they are cut away during a processing step.

[0048] The area where the chamfer is printed can correspond to the area where it is pressed. In one possible embodiment, the printed chamfer area can extend beyond the pressed area. This extension can have various dimensions. Preferably, the printed chamfer area extends beyond the pressed joint area by the tolerances of the machines used. These tolerances can be, for example, 1 mm. This ensures that even minor deviations in the positioning of the pressed chamfer relative to the printed chamfer, e.g., due to inaccurate adjustment, do not result in defects. This serves quality assurance and simultaneously reduces ink consumption. Printing far beyond the tolerance range would also be conceivable, but would have disadvantages in terms of ink consumption.

[0049] Another aspect of the invention relates to a floor panel arrangement, wherein the floor panel arrangement comprises at least two floor panels with the aforementioned features, wherein when the floor panels are joined together, the at least one chamfer of a first floor panel forms a complete joint with the at least one chamfer of a further floor panel.

[0050] The two floor panels can be placed next to each other, either directly or with a slight gap.

[0051] Together, the two chamfers of the at least two floor panels form a complete joint when the chamfers are joined along a length of the floor panel. A panel floor covering comprises a plurality of floor panels that are placed next to each other. A boundary exists between adjacent panels. At the boundary, there can be a direct transition without a visible demarcation, or a visible demarcation, e.g., by two chamfers placed next to each other. The floor panel arrangement according to the invention comprises at least two floor panels. In particular, the floor panels can be identical floor panels. The panels each have a chamfer on at least one edge. In an arrangement of two floor panels, a complete joint is created when the panels are placed next to each other with their chamfers aligned.When more than two floor panels are used, the panels can be joined not only at the bevels but also along their length. A bevel is not mandatory along the length of the panels. In particular, a continuous floor covering can be created when a large number of panels are used. This floor covering will have joints formed by two joined bevels at many of the panel boundaries, while at other boundaries, it will have no joints at all.

[0052] The arrangement of at least two floor panels results in a complete joint being formed at the interface between each pair of panels when they are butted together with their chamfered edges. The depth of the joint appears significantly deeper due to the effect of the chamfer, which enhances the optical depth effect and is located at the edges of the butted panels.

[0053] For example, the chamfers can be printed onto the printing layer and pressed into the floor panel in such a way that half of the joint is located on one panel and the other half on the adjacent panel. Other divisions are also conceivable, e.g., 1 / 3 and 2 / 3, or that the joint is located completely or almost completely (e.g., > 90%) on one of the two panels and the adjacent panel has no or almost no joint (e.g., < 10%).

[0054] An arrangement of multiple floor panels can, for example, be configured such that chamfers are present along the width of each individual panel, formed by the butting edges of the panels together. Preferably, for example, each pair of opposite edges of a panel has a chamfer, so that a complete joint is formed at the boundary between two panels when they are butted together. If, for example, the joint has a V-shape, the chamfer of one panel at one edge can form the right half of a V when the V is divided by a perpendicular cut, for example, in the middle, with the opposite edge of the panel having a chamfer corresponding to the left half of a V, preferably with the deepest point of the chamfer's insertion depth being located at the boundary between the two panels.Preferably, the darkest shade of the effect is located at the point on the panel that is pressed in most deeply, in order to enhance the optical depth effect of a chamfer.

[0055] Another aspect of the invention relates to a method for manufacturing a floor panel with at least one chamfer, wherein the method comprises providing a plate-shaped core with a visible printed layer and an overlay on the visible printed layer, such that the visible printed layer is protected by the overlay. Furthermore, the method comprises pressing at least one chamfer, wherein the printed layer on a surface of the at least one chamfer has an effect to enhance the optical depth effect of the chamfer.

[0056] The overlay is applied to the printed layer so that it at least partially covers it. The overlay can be a layer of paper impregnated with resin and containing abrasion-resistant particles. The overlay can be applied by pulling it from a pallet onto a stack of backing paper, decorative paper, and overlay in front of the short-cycle press, placing it on the stack, and pressing it into a laminate. The overlay can be a liquid overlay. A liquid overlay can comprise one or more layers of liquid resin. Advantageously, abrasion-resistant particles are sprinkled onto at least one of the resin layers. If there are multiple resin layers, intermediate drying can be performed. During intermediate drying, the resin layer is only dried and thus retains a large portion of its reactivity, which is utilized under the pressure and temperature in the short-cycle press.

[0057] This protects the printed layer from damage caused by, for example, mechanical impacts such as walking on it, placing objects on it, or similar actions, thus making the floor panel more durable and resistant. This advantage is particularly evident compared to the conventional prior art method of milling the chamfer and coating it with paint. Milling destroys the overlay in the chamfer area, leaving the subsequently applied paint unprotected. Therefore, the chamfered area is especially susceptible to abrasion and damage. This problem is solved by the method according to the invention.

[0058] Furthermore, the process can include providing a substrate material. The substrate material can be a paper web. The substrate material can have a decorative finish. The substrate material can be positioned between the plate-shaped core and the printing layer.

[0059] Possible printing methods include digital and analog printing. For example, a digital printing system can print the decorations and the optical effect to enhance the depth of the bevel in the same step. In the analog printing method, one or more printing rollers can be used, for example, via indirect gravure printing onto a plate.

[0060] An exemplary system for producing the floor panels according to the invention comprises, for example, an automated panel feeder, priming and drying units, inline primers, and an analog printing system with printing rollers or a digital printing system, a cooling device, and a stacking system. The creation and preparation of the print data can be carried out, for example, in prepress using an image editing program.

[0061] In analog printing, information for the chamfers used to engrave the printing rollers is included in the separation data. Effects, colors, contrast levels, and gradients can be created in image editing programs. Precise positioning is necessary here to ensure that the pressed grooves are accurately aligned with the print in subsequent processing steps. Digital printing makes it relatively easy to implement such groove reinforcement even for existing designs, as only the data needs to be modified. With analog printing, new rollers must also be engraved, incorporating the grooves as a printing element.

[0062] The layers can be applied to each other, for example, by gluing and / or pressing. If pressing is used, pressing the joint portion into the panel can be done separately from pressing the layers in a single step, or in the same step.

[0063] The process steps can be integrated into common manufacturing processes for floor panels without requiring a complete rebuild of the entire production line. This makes the production of floor panels with visually deeper bevels cost-effective and therefore competitive.

[0064] One example concerns a method for manufacturing a floor panel, wherein the application step also includes the application of a decoration which is different in effect and is located outside the area of ​​the at least one chamfer.

[0065] The bevel printing process can be carried out simultaneously with the decorative printing step, allowing for cost-effective integration into existing production processes. This makes the method ideally suited for large-scale producers. Manufacturers of floor panels are typically geared towards mass production, and additional work steps or modifications to large-scale equipment are always associated with significant effort and expense. In industrial digital printing, the effect can be incorporated into the digital print data to enhance the optical depth of the bevel.

[0066] Another example concerns a method for manufacturing a floor panel, wherein the step of applying the effect takes place before the step of applying the overlay, and wherein the pressing step takes place after the step of applying the overlay.

[0067] This offers the advantage that the floor panel is manufactured from the bottom layers to the top layers, so that the next work step always takes place on the top side. This makes production particularly simple, as the panel does not need to be turned over and all machines access the panel from the top.

[0068] Another example concerns a method for manufacturing a floor panel, wherein the step of applying the printing layer, when a substrate material in the form of a paper web is used, includes applying the printing layer beyond the plate-shaped core, pressing the paper web with the plate-shaped core.

[0069] The printed layer is applied in an area that extends beyond the area where it will be visible on the finished panel. For example, the protruding portion of the printed layer is then trimmed or sawn off in a later process step. The advantage of this method is that minor deviations from the planned dimensions and positioning of the printed layer or the other layers of the panel do not result in defects. This allows for a margin of tolerance. For instance, the printed layer can be printed 1 mm beyond the dimensions of the planned panel, and if this area does indeed protrude in the finished panel, it is then trimmed away.

[0070] In the figures, identical reference symbols denote functionally equivalent elements. Fig. 1 shows an exemplary cross-section of a floor panel as a possible embodiment of the invention, in which a chamfer is located in the panel; Fig. 2 shows an exemplary cross-section of a floor panel as a possible embodiment of the invention; Fig. 3 shows an exemplary cross-section of a floor panel in which a complete joint is located in the panel; Fig. 4 shows an exemplary cross-section of two floor panels placed next to each other, each having a chamfer; Fig. 5 shows an exemplary cross-section of a floor panel having a complete joint in the middle of the panel width and chamfers at the panel edge; Fig. 6 shows a top view of two exemplary floor panels placed next to each other, each with a chamfer; and

[0071] Fig. 1 Figure 1 shows a cross-section of a floor panel 1. The floor panel 1 has, among other things, a plate-shaped core 20. The plate-shaped core 20 can be made of, for example, wood, stone, plastic, concrete, metal, or other materials; in particular, it can be made of a fiberboard panel. A printing layer 40 is arranged on the top surface 22 of the plate-shaped core 20. An overlay 50 is arranged on the printing layer 40. The printing layer 40 contains an effect to enhance the optical depth effect of a chamfer 24. The printing layer 40 can additionally have a decoration 70 and / or control characters for positioning during pressing. Further layers are optional. The layer thickness, which runs along the y-axis, is freely selectable within the material-specific limits.

[0072] In one possible embodiment, the plate-shaped core 20 can have a significantly greater layer thickness than the printed layer 40 and the overlay 50. A chamfer 24 is arranged on an edge 5 of the base panel 1. The chamfer 24 is pressed into the panel 1 to a depth t. Possible values ​​of t are freely selectable. Examples of the pressing depth t are 0.2–0.6 mm. The shape of the chamfer 24 can be, for example, V-shaped, where the chamfer can be, for example, half of a V or another portion of the entire V. Other possible chamfer shapes can be, for example, a U-shape, a rectangle, a parabola, a circular arc, or combinations thereof, and this list is not exhaustive. The further edge 5, shown with a wavy line, can optionally have, for example, a chamfer 24, no chamfer, or a complete joint 25.The base panel 1 can optionally include further layers, which can be arranged on the top, bottom, and / or between the aforementioned layers. In this embodiment, however, the base panel 1 is provided to have only a plate-shaped core 20, a pressure layer 40, and an overlay 50.

[0073] In Fig. 2 The cross-section of another embodiment is shown, which is a variant of the one described in Fig. 1 The illustrated embodiment shows the exemplary embodiment depicted. The in Fig. 2 The illustrated embodiment differs from the variant in Fig. 1 in that the base panel 1 additionally has a carrier material 30. The carrier material 30 is arranged on the top surface 22 of the plate-shaped core. The carrier material 30 can, for example, be a paper web. The printing layer 40 is applied to the carrier material 30 on a first side 32. The first side 32 is the top surface, i.e., the side of the carrier material that faces the plate-shaped core.

[0074] In Fig. 3 The cross-section of another embodiment is shown, which is a variant of the one described in Fig. 1 The illustrated embodiment shows the exemplary embodiment depicted. The in Fig. 3 The illustrated embodiment differs from the variant in Fig. 1 in that a complete joint 25 is arranged at the edge 5 of the panel 1, whereas in the variant in Fig. 1 A chamfer 24 is arranged at the edge 5 of the panel. The complete joint 25 shown has the shape of a V as an example. Other shapes of the joint 25, such as a U, a circular arc, a rectangle, and others, are possible.

[0075] The in Fig. 4 The embodiment shown in cross-section is a variant of the one described in Fig. 1 The illustrated embodiment differs in that a second joint 60 is arranged in the middle of the floor panel 1. Chamfers 24 or complete joints 25 can also be arranged at each of the two edges 5 of the floor panel 1. In this example, there is a chamfer 24 in the shape of a half V at each edge 5 of the panel 1 and a complete V-shaped joint 25 in the middle.

[0076] Fig. 5 Figure 1 shows a cross-section of a floor panel arrangement 100 consisting of two floor panels 1 placed next to each other. In this example, the floor panels 1 are like the panel 1 in [reference missing]. Fig. 1 executed. Alternatively, the panels 1 can be installed, for example, as shown in Fig. 2 , 3 or 4 The two panels 1 can be arranged side by side in such a way that the two chamfers 24 at the edge 5 of the panels 1 together form a complete joint 25. For example, there may be a narrow gap between the edges 5 of the two panels 1, or the two panels 1 may be in direct contact with each other. The shape of the joint 25 or the chamfers 24 can be V-shaped in cross-section. Other possible embodiments may have differently shaped chamfers 24 or joints 25.

[0077] In Fig. 6 Figure 1 shows a top view of two adjacent floor panels 1. The floor panels 1 can have cross-sections like those shown in Figure 2. Fig. 1-4 The floor panels 1 shown. For example, the cross-sections of the adjoining floor panels 1 can be as shown in Fig. 5The cross-sections shown are as follows. Other cross-sections are also possible. A chamfer 24 is arranged at the edge 5 of each of the two floor panels 1. The two floor panels 1 are positioned so that the two chamfers 24 together form a complete joint 25. The surface of the chamfer 24 at the edge 5 of the floor panels 1 is printed with an optical effect to enhance the depth effect of the chamfer 24. In one possible embodiment, the area of ​​the printed chamfer 24 can have the same extent in the x and / or z direction as the area in which the chamfer 24 is pressed. In another possible embodiment, the area of ​​the printed chamfer 24 can extend beyond the area of ​​the pressed chamfer 24 in the x and / or z direction.

[0078] The floor panel 1 can have a decor 70. The decor 70 can be designed, for example, as an imitation of wood, stone, concrete, or other materials, or as any pattern. In the example shown, the decors 70 of both panels 1 are identical. In another embodiment, the panels 1 can have different decors 70.

[0079] An exemplary method for manufacturing a floor panel 1 with a chamfer 24 comprises providing a plate-shaped core 20 with a visible printed layer 40 and an overlay 50 on the visible printed layer 40, such that the visible printed layer 40 is protected by the overlay 50. The method further comprises pressing the chamfer 24 so that a bevel is formed in the cross-section of the floor panel in the area of ​​the chamfer 24. The printed layer 40 includes an effect to enhance the depth of the chamfer 24. The method can further include coating the printed layer 40 with an overlay 50.

[0080] The plate-shaped core 20 can be, for example, a fiberboard or made of solid wood, other composite wood, plastic, concrete, stone, or metal, or combinations thereof, and this list is not exhaustive. The application of the printing layer 40 can be carried out, for example, using digital or analog printing. In a further step, the print data can be processed and / or created. The print data includes data for printing the effect to enhance the visual impact of the chamfer 24. Optionally, the print data can also include data for printing a decorative element 70. Optionally, the print data can also include data for printing control characters or markings. The control characters or markings are designed to align the machines used to press the joint into the panel. If an analog printing process is used, the printing rollers can be manufactured in a preliminary step.The printing rollers are manufactured to be aligned with the effect of enhancing the optical effect of chamfer 24 on the printing layer 40. Optionally, the printing rollers can also be configured to print a decorative element 70 and / or control characters or markings.

[0081] The process can include a step for pressing the carrier material 30 with the plate-shaped core 20. The process can include a step for bonding the carrier material 30 to the plate-shaped core 20. The process can include a step for pressing and / or bonding the overlay 50 to the printing layer 40. If a pressing step is used, it can be performed separately from the step of pressing the chamfer 24 into the panel 1 or simultaneously with it.

[0082] An exemplary process for manufacturing a floor panel 1 with a chamfer 24 comprises: providing a plate-shaped core 20, e.g., in the form of a fiberboard, and a substrate 30, e.g., in the form of a paper web; optionally impregnating the paper web, e.g., with a resin; then bonding the substrate 30 to the plate-shaped core 20; subsequently printing the provided print data onto the substrate 30 using a digital printing process, wherein the print data includes a decor 70, control characters for positioning the presses, and an optical effect to enhance the optical depth of the chamfer 24, which can be, for example, a color gradient from brown to black. The decor 70 can be, for example, a wood decor; other examples are imitations of cork, concrete, stone, fantasy decors, or any pattern. After applying the print layer 40, an overlay 50 is applied to it, e.g., by bonding.The overlay 50 protects the printed layer 40 from scratches, abrasion, and other mechanical influences and is preferably liquid-repellent. A chamfer 24 is then pressed into the panel 1, the area into which the chamfer 24 is pressed overlapping at least partially with the area where the effect for enhancing the optical depth of the chamfer 24 is printed. For example, the chamfer 24 can have a V-shape and be pressed into a panel 1. Preferably, the deepest point along the pressed-in depth t of the chamfer 24 corresponds to the darkest shade of the printed effect for enhancing the optical depth of the chamfer 24. Optionally, it is possible to incorporate further layers and steps into this process, e.g., applying a layer to the underside of the plate-shaped core 10, i.e., on the side opposite the printed layer 40.Additional layers between the other layers are optional.

[0083] The effect of making the chamfer appear deeper can be achieved by printing a three-dimensional effect to enhance the optical depth of a chamfer precisely in the area where the pressed chamfer 24 is located.

[0084] The effect for enhancing the optical depth of a chamfer 24 can be adjusted in various ways to the decor 70 or its color scheme to achieve the desired degree of visual depth. The printing of the chamfer 24, for example, takes place simultaneously with the decor printing step and can thus be integrated cost-effectively into existing production processes. This makes the process very well suited for large-scale producers. Manufacturers of floor panels are generally geared towards mass production, and additional work steps or modifications to large-scale production lines are always associated with significant effort and costs.

[0085] In industrial digital printing, chamfers 24 can be incorporated into the digital print data. In analog printing, information for the joints used to engrave the printing rollers is included in the separation data. The effects / colors / contrast levels / gradients can be created in image editing programs. Precise positioning is necessary here to accurately match the area of ​​the pressed chamfer 24 and the area of ​​the effect for enhancing the optical depth of the chamfer 24 in the printing layer 40 during the subsequent processing steps. In digital printing, such an effect for enhancing the optical depth of a chamfer 24 can be implemented quite easily for existing decors 70, as only the data needs to be modified. In analog printing, new rollers must also be engraved, in which the effect for enhancing the optical depth of a chamfer 24 is included as a printed element.

[0086] There are several ways in which the effect to enhance the optical depth of a chamfer 24 can be printed.

[0087] One example is that the effect to enhance the optical depth of a chamfer 24 is printed only in the area that corresponds to the area of ​​the pressed chamfer 24 after further processing.

[0088] This has the advantage of saving ink, as the effect for enhancing the optical depth of a chamfer 24 is only printed where it is actually needed. Another option is to print the area where the effect for enhancing the optical depth of a chamfer 24 is printed slightly (e.g., up to 1 mm) beyond the actual panel edge 5 to compensate for any tolerances or prevent defects. This is the preferred option due to its favorable balance of quality assurance and ink consumption. In another example, the entire area between the panel transitions is printed with the effect for enhancing the optical depth of a chamfer 24. This means that areas that will be sawn away or profiled in subsequent processing steps and therefore will not be visible in the final format are also printed.This area consumes a particularly large amount of ink, which could lead to an unfavorable cost situation.

[0089] Control marks in contrasting colors can also be printed to align downstream processing equipment. These can be lines, dots, or similar symbols. The goal is to position the areas of the printed effects, which enhance the optical depth of a chamfer 24, using optical alignment systems so that they correspond precisely to the area where the chamfer 24 is pressed.

[0090] Furthermore, these control marks can also be used for alignment when sawing the panels. In another embodiment, the joint elements can also be located additionally or exclusively in the middle of the floor panel and not only at panel joints. This can be the case, for example, with a panel that imitates a herringbone pattern. The individual edges 5 of the panels 1 or the individual areas of the pressed chamfer 24 can be printed with an effect to enhance the optical depth of a chamfer 24, and a chamfer 24 can also be pressed.

[0091] Any color variation is possible that lies within the possible color space in order to achieve the best possible depth effect in the effect for enhancing the optical depth effect of a chamfer 24.

[0092] This can include, for example, solid colors, straight gradients, or even textured / speckled variations thereof. Halftones or line combinations are also possible to achieve specific effects. Especially in digital printing, there are virtually no limits. Example 1 - Digital printing on paper

[0093] At a manufacturer of laminate flooring planks, decorative paper webs with wood, stone, and fantasy designs are printed using an industrial digital printer. The paper web is up to 2070 mm wide and has a basis weight of 50-65 g / m². The paper is primed inline with 3-6 g / m². The printing system can produce 50 million m² or more of decorative paper per year.

[0094] The creation and preparation of the print data takes place in prepress using image editing programs. The manufacturer's sales department / customer requests an oak decor in a natural color tone with a particularly pronounced chamfer (24) or, when placed side by side, a particularly pronounced joint (25). This is to be achieved with a combination of printed and pressed chamfers (24).

[0095] The pressed structure for the decor contains areas where the chamfers are pressed, making the joints visible at the edges 5 of the finished panel 1. For printing the effect to enhance the optical depth of a chamfer 24, a gradient from black to deep brown is desired. When creating the print data, a black / brown gradient is created at the positions that correspond to the panel edge 5 after further processing. The gradient is designed so that black is printed at the deepest point of the pressed chamfer 24 along the indentation depth t, and brown fades to the surface level. Additionally, markings are inserted into the print data at the positions that will be omitted during the subsequent sawing and profiling steps. These markings are used both for aligning the impregnated paper sheets in the short-cycle press using cameras and a control unit, and for aligning the pressed panels during sawing.This ensures that the areas where the effect is printed to enhance the optical depth of a chamfer 24 are located precisely on the surrounding edges 5 of the finished panel, or within the area of ​​the pressed chamfer. The printed color gradient in the area of ​​the pressed chamfer makes it appear much deeper. The contrast with the natural oak color is high and stands out clearly from the rest of the installed flooring. Without this optical enhancement through the printed effect to increase the optical depth of a chamfer 24 in the area of ​​the pressed chamfer 24, the sales department's request would not have been possible.

[0096] The surface quality of the chamfer 24 is significantly better protected by the pressed chamfer 24 over the printed layer 40, which incorporates the effect to enhance the optical depth of the chamfer 24, and the overlying overlay 50, than if the edge had to be milled out for coating, as in other conventional methods. By applying this method, the optical effect could be significantly altered without any loss of quality. This gives the manufacturer a significant competitive advantage, enabling them to sell their products more effectively on the market. Example 2 - Digital printing on board

[0097] At a manufacturer of laminate flooring planks, wood, stone, and fantasy decors are digitally printed onto high-density fiberboard (HDF) panels. The panels are 2800 mm long, 2070 mm wide, and 6-12 mm thick. The entire system has a feed speed of 80 m / min with a panel gap of approximately 1500 mm and is fully automated. The system includes automated panel feeding, priming and drying units, an inline primer and digital printing unit, a cooling system, and a stacking unit.

[0098] The creation and preparation of the print data takes place in prepress using image editing software. A customer of the manufacturer has requested a concrete decor in a medium gray tone with a particularly deep chamfer (24). This is to be achieved using a combination of printed and pressed chamfers (24).

[0099] The press structure for decor 70 contains areas where chamfers 24 are pressed, which become visible at the edges 5 of the finished panel. A gradient from dark anthracite to black is used to print the effect that enhances the optical depth of a chamfer 24. When creating the print data, an anthracite / black gradient is created at the positions that correspond to the panel edges 5 after further processing. The gradient is designed so that black is printed at the deepest point of the pressed chamfer 24 and fades to brown at the surface level. Additionally, markings are inserted into the print data at the positions that will be omitted during the sawing and profiling process. These markings are used for alignment by cameras and a control unit of the impregnated paper sheets in the short-cycle press and of the pressed panels during sawing.This ensures that the printed effects for enhancing the optical depth of a chamfer 24 are located precisely at the surrounding edges 5 of the finished panel, or within the area of ​​the pressed chamfer 24. The printed color gradient, used as an effect to enhance the optical depth of the chamfer 24 in the area of ​​the pressed chamfer 24, makes it appear much deeper. The contrast with the mid-gray tone is high and stands out clearly from the rest of the installed flooring. Without this effect, which enhances the optical depth of the chamfer 24 through printing in the area of ​​the pressed chamfer 24, the sales department's request would not be feasible.The surface quality of the chamfer 24 is also significantly more protected with the pressed chamfer 24 over the printing layer 40, which contains the effect to enhance the optical depth effect of a chamfer 24 and the overlying overlay 50, than if the edge had to be milled out to coat it with paint as in other common methods.

[0100] By applying this method, the optical effect could be significantly altered without any loss of quality. This gives the manufacturer a significant competitive advantage, enabling them to sell their products more effectively on the market. Example 3 - Analog printing on plate

[0101] At a manufacturer of laminate flooring planks, wood, stone, and fantasy decors are digitally printed onto high-density fiberboard (HDF) panels. The panels are 2800 mm long, 2070 mm wide, and 6-12 mm thick. The entire system has a feed speed of 80 m / min with a panel gap of approximately 1500 mm and is fully automated. The system includes automated panel feeding, priming and drying units, an inline primer, an analog printing unit / printing rollers for indirect gravure printing on the panel, a cooling unit, and a stacking system.

[0102] The creation and preparation of the print data takes place in prepress using image editing software. For the manufacturer's new collection, a dark brown walnut decor with a particularly deep chamfer (24) is desired. This is to be achieved using a combination of printed and pressed chamfers (24).

[0103] The press structure for decor 70 contains areas where the chamfers are pressed, which become visible at the edges of the finished panel. A gradient from dark gray to black is used to print the effect that enhances the optical depth of a chamfer. When creating the print data, an anthracite / black gradient is created at the positions that correspond to the chamfered edge after further processing. The gradient is designed so that black is printed at the lowest point of the pressed chamfer and dark gray fades to the surface level. Additionally, markings are inserted into the print data at the positions that will be removed during the sawing and profiling process. These markings are used both for aligning the impregnated paper sheets in the short-cycle press using cameras and a control unit, and for aligning the pressed panels during sawing.This ensures that the printed chamfer is located precisely on the surrounding edges 5 of the finished panel or in the area of ​​the pressed chamfer 24.

[0104] The printed color gradient in the area of ​​the pressed chamfer 24 makes it appear much deeper. The contrast to the medium gray tone is high and stands out clearly from the rest of the laid flooring. Without this effect, which enhances the optical depth of the chamfer 24 through printing in the area of ​​the pressed chamfer 24, the sales department's request would not have been possible. The surface quality of the joint is also significantly better protected with the pressed joint over the printed layer 40, which contains the effect to enhance the optical depth of the chamfer, and the overlying overlay 50, than if the edge had to be milled out for painting, as in other conventional methods. By applying this process, the optical effect could be significantly altered without any loss of quality.

[0105] In one example, the floor panel 1 can have at least a part of a joint 25, wherein the floor panel 1 comprises: a plate-shaped core 20, a substrate material 30, a printing layer 40 applied to the substrate material 30 within a first area on a first side 32 of the substrate material 30, wherein the printing layer 40 in the first area has an effect to enhance an optical depth effect of the joint 25; an overlay 50 on the printing layer 40, such that the printing layer 40 is protected by the overlay 50; and at least a part of the at least one joint 25 in a second area, which is pressed from the first side 32 through the substrate material 30 into the plate-shaped core 20, wherein the second area is arranged within the first area, wherein the joint 25 has a width which differs from an indentation depth t and a longer side of the joint 25.

[0106] In a second example, the floor panel 1 can be constructed as in the first example, with the plate-shaped core 20 being the support material 30.

[0107] In a third example, the floor panel 1 can be constructed as in the first example, where the carrier material 30 is a paper web.

[0108] In a fourth example, the floor panel 1 can be constructed as in the first, second or third example, wherein part of the at least one joint 25 is arranged such that it forms at least one edge 5 of the floor panel 1.

[0109] In a fifth example, the floor panel 1 can be configured as in one of the previous examples, wherein at least one part of the at least one joint 25 corresponds to half of the joint 25 along the width of the joint 25.

[0110] In a sixth example, the floor panel 1 can be constructed as in one of the previous examples, with the joint having a V-shape along its width in cross-section.

[0111] In a seventh example, the floor panel 1 can be of the same design as in one of the previous examples, with the insertion depth t of the joint being between 0.2 mm and 0.6 mm.

[0112] In an eighth example, the floor panel 1 can be as in one of the previous examples, wherein the effect has a color gradient along the width, wherein the color gradient changes its color and / or brightness, wherein in particular the color and / or brightness is darkest at a center of the width of the joint 25 and / or increases along the width with distance from the center.

[0113] In a ninth example, the floor panel 1 can be constructed as in one of the previous examples, wherein the floor panel 1 has a further second joint 25 which is different from at least part of the at least one joint 25.

[0114] In a tenth example, the floor panel 1 can be designed as in one of the previous examples, wherein the printed layer 40 has, in addition to the effect, a decor 70 that differs from the effect and is arranged outside the at least one joint 25.

[0115] In one example, a floor panel arrangement 100 can comprise at least two floor panels 1 according to one of the previous examples, where in one

[0116] Joining a first part of the joint 25 of a first of the at least two floor panels 1 with a part of the joint 25 of another of the at least two floor panels 1, the respective parts of the joint 25 forming a complete joint 25.

[0117] In an example, a method for manufacturing a floor panel 1 with at least part of a joint 25 may include the following steps: Providing a plate-shaped core 20; providing a support material 30; applying a printing layer 40 to the support material 30 within a first area on a first side 32, wherein the printing layer 40 in the first area has an effect to enhance an optical depth effect of the joint 25; coating the printing layer 40 with an overlay 50 on the first side 32, such that the printing layer 40 is protected by the overlay 50; and pressing at least a part of the at least one joint 25 in a second area from the first side 32 through the support material 30 into the plate-shaped core 20, wherein the second area is arranged within the first area, wherein the joint 25 has a width which differs from an indentation depth t and a longer side of the joint 25.

[0118] In another example, a process can be like the one in the previous example, wherein the application step also includes the application of a decoration 70 which is different in effect and is arranged outside at least part of the at least one joint 25.

[0119] In another example, a process can be like the two previous examples, wherein the step of applying the effect takes place before the step of applying the overlay 50, and wherein the pressing step takes place after the step of applying the overlay 50.

[0120] In another example, a process can be like the previous examples, wherein the step of applying the printing layer 40, when the substrate 30 is a paper web, includes applying the printing layer 40 beyond the plate-shaped core 20, pressing the paper web with the plate-shaped core 20. Reference symbol list

[0121] 1 Floor panel 5 Edge of floor panel 20 Plate-shaped core 22 Top of plate-shaped core 24 Bevel 25 Full joint 30 Carrier material 32 First side of carrier material 40 Print layer 50 Overlay t Press-in depth 70 Decor 100 Floor panel arrangement

Claims

1. Floor panel (1), wherein the floor panel comprises: - a plate-shaped core (20); - a visible print layer (40); - an overlay (50) on the visible print layer (40) such that the visible print layer (40) is protected by the overlay (50); and - at least one bevel (24), wherein the visible print layer (40) on a surface of the at least one bevel (24) has an effect for enhancing an optical depth effect of the bevel (24), wherein the effect comprises a color gradient from a darker color tone at the deepest pressed point of the chamfer to a lighter color tone at an unpressed area, characterized in that the chamfer (24) is pressed into the plate-shaped core (20) through the overlay (50).

2. Floor panel (1) according to claim 1, wherein the visible printed layer (20) is applied to a carrier material (30) other than the plate-shaped core.

3. Floor panel (1) according to claim 2, wherein the carrier material (30) is a paper layer.

4. Floor panel (1) according to one of the previous claims, wherein at least one of the at least one bevel (24) is arranged such that it forms at least one edge (5) of the floor panel (1).

5. Floor panel (1) according to claim 4, wherein a further edge (5) opposite the edge (5) has at least one chamfer (24).

6. Floor panel (1) according to one of the previous claims, wherein a press-in depth (t) of the chamfer (24) is between 0.2 mm and 0.6 mm.

7. Floor panel (1) according to one of the preceding claims, wherein the floor panel (1) has a second bevel and a third bevel such that the second bevel and third bevel form a joint (25), wherein the joint (25) is spaced apart from the edge (5) of the floor panel (1).

8. Floor panel (1) according to one of the previous claims, wherein the print layer (40) additionally has a decoration (70) different from the effect, which is arranged outside the at least one bevel (24).

9. Floor panel arrangement (100) comprising at least two floor panels (1) according to one of the previous claims, wherein when the floor panels (1) are joined together, the at least one chamfer (24) of a first floor panel forms a complete joint (25) with the at least one chamfer (24) of a further floor panel (1).

10. Floor panel arrangement (100) according to claim 10, wherein the joint has a V-shaped and / or U-shaped cross-section.

11. Method for manufacturing a floor panel (1) with at least one bevel (24) according to one of the preceding claims 1 to 8, wherein the method comprises the following steps: - providing a plate-shaped core (20), a visible print layer (40) and an overlay (50) on the visible print layer (40) so that the visible print layer (40) is protected by the overlay (50); and - pressing at least one chamfer (24) from the first side (32) into the plate-shaped core (20), wherein the print layer (40) on a surface of the at least one chamfer (24) has an effect for enhancing an optical depth effect of the chamfer (24), wherein the effect has a color gradient from a darker color tone at the deepest pressed point of the chamfer to a lighter color tone at an unpressed area.

12. Method according to claim 11, wherein the step of applying the print layer (40) also comprises applying a decoration (70) which is different from the effect and is arranged outside the surface of the at least one chamfer (24).